ym om v2 cover - j/109j109.org/docs/yanmar_ym_series_operations_manual_v2_21... · 2015. 2. 3. ·...

YMseries

YM Series Operation ManualOPERATION MANUAL

2YM153YM203YM30

P/N: 0AYMM-G00200

MARINEENGINES

ii YM Series Operation Manual© 2009 Yanmar Marine International

Disclaimers:

All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and / or specifications to explain and / or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries.

All Rights Reserved:

No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of Yanmar Marine International.

© 2009 Yanmar Marine International

0109

YM Series Operation Manual iii© 2008 Yanmar Marine International

TABLE OFCONTENTS

Page

Introduction..................................................................... 1Record of Ownership ................................................. 2

Safety ............................................................................... 3Safety Precautions ..................................................... 4

General Information............................................. 4Before You Operate............................................. 4During Operation and Maintenance..................... 5

Location of Safety Decals .......................................... 8

Product Overview ........................................................... 9Yanmar YM Features and Applications...................... 9

New Engine Break-In......................................... 10Component Identification ......................................... 11

Right Side (from Flywheel) - 2YM15.................. 11Left Side (from Flywheel) - 2YM15 .................... 11Right Side (from Flywheel) - 3YM20.................. 12Left Side (from Flywheel) - 3YM20 .................... 12Right Side (from Flywheel) - 3YM30.................. 13Left Side (from Flywheel) - 3YM30 .................... 13

Location of Nameplates ........................................... 14Function of Major Components ................................ 15Control Equipment ................................................... 16

Instrument Panel (Optional)............................... 16Single-Lever Remote Control Handle ................ 20

Before You Operate ...................................................... 21Safety Precautions ................................................... 21Introduction .............................................................. 21Diesel Fuel ............................................................... 22

Diesel Fuel Specifications ................................. 22Filling the Fuel Tank .......................................... 25Bleeding the Fuel System.................................. 26

TABLE OF CONTENTS

iv YM Series Operation Manual© 2008 Yanmar Marine International

Engine Oil ................................................................. 27Engine Oil Specifications .................................. 27Engine Oil Viscosity ........................................... 28Checking the Engine Oil..................................... 28Adding Engine Oil .............................................. 29

Marine Gear or Sail Drive Oil.................................... 29Marine Gear Oil Specifications........................... 29Sail Drive Oil Specifications - SD20 ................... 29Checking Marine Gear Oil.................................. 30Adding Marine Gear Oil...................................... 30Checking and Adding Sail Drive Oil ................... 30

Engine Coolant ......................................................... 31Engine Coolant Specifications ........................... 31Checking and Adding Coolant............................ 31

Cranking the Engine ................................................. 34

Engine Operation .......................................................... 35Safety Precautions ................................................... 35Introduction............................................................... 36Starting the Engine ................................................... 37

Restarting After Starting Failure......................... 37Starting at Low Temperatures............................ 38After the Engine has Started .............................. 38

Remote Control Handle Operation ........................... 39Acceleration and Deceleration ........................... 39Shifting the Engine ............................................. 40

Shutting Down the Engine ........................................ 40Emergency Shutdown ........................................ 41

Checking the Engine After Operation ....................... 42

Periodic Maintenance ................................................... 43Safety Precautions ................................................... 43Introduction............................................................... 45Precautions............................................................... 45

The Importance of Periodic Maintenance .......... 45Performing Periodic Maintenance ...................... 45The Importance of Daily Checks ........................ 45Keep a Log of Engine Hours and Daily Checks . 46Yanmar Replacement Parts ............................... 46Tools Required................................................... 46Ask Your Authorized Yanmar Marine Dealer or Distributor for Help ............................................. 46Tightening Fasteners ......................................... 47

EPA Maintenance Requirements ............................. 48EPA Requirements for USA and Other Applicable Countries .......................................... 48Conditions to Ensure Compliance with EPA Emission Standards ........................................... 48

TABLE OF CONTENTS

YM Series Operation Manual v

12/05


Inspection and Maintenance.............................. 48Installing Sample Port........................................ 48

Periodic Maintenance Schedule............................... 50Inspection and Maintenance of EPA Emission-Related Parts ..................................... 54

Periodic Maintenance Procedures ........................... 55Daily Checks...................................................... 55After Initial 50 Hours of Operation ..................... 56Every 50 Hours of Operation ............................. 60Every 100 Hours of Operation ........................... 62Every 150 Hours of Operation ........................... 63Every 250 Hours of Operation ........................... 63Every 1000 Hours of Operation ......................... 66

Troubleshooting .......................................................... 69Safety Precautions ................................................... 69Troubleshooting After Starting ................................. 69

Troubleshooting Information.............................. 70Troubleshooting Chart.............................................. 71

Long-Term Storage ...................................................... 75Safety Precautions ................................................... 75Introduction .............................................................. 75Prepare Engine for Long-Term Storage................... 76Draining the Cooling System.................................... 76

Specifications ............................................................... 79Principal Engine Specifications ................................ 79

2YM15 Engine Specifications............................ 793YM20 Engine Specifications............................ 813YM30 Engine Specifications............................ 83Marine Gear and Sail Drive Specifications ........ 85

System Diagrams ......................................................... 87Piping Diagrams....................................................... 87Wiring Diagrams....................................................... 93

EPA Warranty USA Only .............................................. 99Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only................................... 99

Your Warranty Rights and Obligations: ........... 100Warranty Period:.............................................. 100Warranty Coverage: ........................................ 101Exclusions: ...................................................... 101Owner’s Responsibility: ................................... 101Customer Assistance:...................................... 102

Emission System Warranty ....................................... 103Non-Road Emission System Warranty................... 103

Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only .......................... 103

TABLE OF CONTENTS

vi YM Series Operation Manual© 2008 Yanmar Marine International

Maintenance Log.............................................. 106

YM Series Operation Manual 1© 2009 Yanmar Marine International

YM Series Operation Manual INTRODUCTION

Welcome to the world of Yanmar Marine! Yanmar Marine offers engines, drive systems and accessories for all types of boats, from runabouts to sailboats, and from cruisers to mega yachts. In marine leisure boating, the worldwide reputation of Yanmar Marine is second to none. We design our engines to respect nature. This means quieter engines, with minimal vibrations, cleaner than ever. All of our engines meet applicable regulations, including emissions, at the time of manufacture.

To help you enjoy your Yanmar YM series engine for many years to come, please follow these recommendations:

• Read and understand this Operation Manual before you operate the engine to ensure that you follow safe operating practices and maintenance procedures.

• Keep this Operation Manual in a convenient place for easy access.

• If this Operation Manual is lost or damaged, order a new one from your authorized Yanmar Marine dealer or distributor.

• Make sure this manual is transferred to subsequent owners. This manual should be considered a permanent part of the engine and remain with it.

• Constant efforts are made to improve the quality and performance of Yanmar products, so some details included in this Operation Manual may differ slightly from your engine. If you have any questions about these differences, please contact your authorized Yanmar Marine dealer or distributor.

• The specifications and components (instrument panel, fuel tank, etc.) described in this manual may differ from ones installed on your vessel. Please refer to the manual provided by the manufacturer of these components.

• Refer to the Yanmar Limited Warranty Handbook for a complete warranty description.

INTRODUCTION

2 YM Series Operation Manual© 2009 Yanmar Marine International

RECORD OF OWNERSHIPTake a few moments to record the information you need when you contact Yanmar for service, parts or literature.

Engine Model: __________________________________________________________

Engine Serial No.: _______________________________________________________

Date Purchased: ________________________________________________________

Dealer:_________________________________________________________________

Dealer Phone:___________________________________________________________


YM Series Operation Manual

SAFETYYanmar considers safety of great importance and recommends that anyone who comes in close contact with its products, such as those who install, operate, maintain or service Yanmar products, exercise care, common sense and comply with the safety information in this manual and on the engine’s safety decals. Keep the decals from becoming dirty or torn and replace them if they are lost or damaged. Also, if you need to replace a part that has a decal attached to it, make sure you order the new part and decal at the same time.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a situation which can cause damage to the engine, personal property and / or the environment or cause the equipment to operate improperly.

A

This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alert symbol.

SAFETY


SAFETY PRECAUTIONSGeneral InformationThere is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operation or performing repairs or maintenance.

Before You Operate

The safety messages that follow have DANGER level hazards.

NEVER permit anyone to install or operate the engine without proper training.

• Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures.

• Safety signs and decals are additional reminders for safe operating and maintenance techniques.

• See your authorized Yanmar Marine dealer or distributor for additional training.

SAFETY

YM Series Operation Manual 5

12/05


During Operation and Maintenance

The safety messages that follow have WARNING level hazards.

Explosion HazardWhile the engine is running or the battery is charging, hydrogen gas is being produced and can be easily ignited. Keep the area around

the battery well-ventilated and keep sparks, open flames and any other form of ignition out of the area.

Fire and Explosion HazardDiesel fuel is flammable and explosive under certain conditions.

NEVER use a shop rag to catch the fuel.

Wipe up all spills immediately.

NEVER refuel with the engine running.

Store any containers containing fuel in a well-ventilated area, away from any combustibles or sources of ignition.

Fire HazardUndersized wiring systems can cause an electrical fire.

Ensure that appropriate fire detection and extinguishing equipment are installed and checked periodically for proper operation.

Coolant may be flammable under certain conditions. NEVER allow coolant to come into contact with hot surfaces or insulation material.

Sever HazardNEVER wear jewelry, unbuttoned cuffs, ties or loose-fitting clothing and ALWAYS tie back long hair when working near moving /

rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts.

The propeller may rotate during towing or ifthe engine is running at idle speed. NEVERservice the engine while being towed orwhen the engine is running.

If the vessel has more than one engine,NEVER service an engine if either of theengines is running. In multi-engineconfigurations the propeller for an enginethat is shut down may rotate if any of theother engines are running.

NEVER operate the engine without theguards in place.

Alcohol and Drug HazardNEVER operate the engine while under the influence of alcohol or drugs or if you are feeling ill.

Exposure HazardALWAYS wear personal protective equipment including appropriate clothing, gloves, work shoes, eye and hearing protection

as required by the task at hand.

SAFETY


Burn HazardSome of the engine surfaces become very hot during operation and shortly after shutdown. Keep hands and other body parts away from

hot engine surfaces.

Exhaust HazardNEVER block windows, vents or other means of ventilation if the engine is operating in an enclosed area. All internal combustion engines create

carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning.

Sudden Movement HazardNEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals.

The safety messages that follow have CAUTION level hazards.

Poor Lighting HazardEnsure that the work area is adequately illuminated. ALWAYS install wire cages on portable safety lamps.

Tool HazardALWAYS use tools appropriate for the task at hand and use the correct size tool for loosening or tightening engine parts.

Flying Object HazardALWAYS wear eye protection when servicing the engine or when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.

Coolant HazardWear eye protection and rubber gloves when you handle Long Life engine coolant. If contact with the eyes or skin should occur,

flush eyes and wash immediately with clean water.

SAFETY


12/05


The safety messages that follow have NOTICE level hazards.

It is important to perform daily checks as listed in the Operation Manual.

Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor engine performance and helps extend the life of the engine.

See your authorized Yanmar Marine dealer or distributor if you need to operate the engine at high altitudes. At high altitudes the engine will lose power, run rough and produce exhaust gases that exceed the design specifications.

ALWAYS be environmentally responsible.

Follow the guidelines of the EPA or other governmental

agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility.

NEVER dispose of hazardous materials by dumping them into a sewer, on the ground or into ground water or waterways.

If a Yanmar Marine Engine is installed at an angle that exceeds the specifications stated in the Yanmar Marine Installation Manuals, engine oil may enter the combustion chamber causing excessive engine speed, white exhaust smoke and serious engine damage. This applies to engines that run continuously or those that run for short periods of time.

If you have an installation with two or three engines and only one engine is operating, the seacock of the non-running engine(s) should be closed. This will prevent water from being forced past the seawater pump and entering the engine. The result of water entering the engine could cause engine seizure or other serious problems.

If you have an installation with two or three engines, and only one engine is operating, please note that if the propeller shaft thru-hull (stuffing box) is lubricated by engine water pressure and the engines are interconnected, care must be taken that water from the running engine does not enter the exhaust of the non-running engine(s). This water could cause seizure of the non-running engine(s). See your authorized Yanmar Marine dealer or distributor for a complete explanation of this condition.

If you have an installation with two or three engines, and only one engine is operating, it is important to limit the amount of throttle applied to the running engine. If you observe black smoke or movement of the throttle does not increase engine rpm, you are overloading the engine that is running. Immediately throttle back to approximately two-thirds throttle or to a setting where the engine performs normally. Failure to do so may cause the running engine to overheat or cause excess carbon buildup which may shorten the engine's life.

NEVER turn off the battery switch (if equipped) or short the battery cables during operation. Damage to the electrical system will result.

SAFETY


LOCATION OF SAFETY DECALSFigure 1 shows the location of safety decals on Yanmar YM series marine engines.

Figure 1YM Engines

Figure 1

1 – Part Number: 128377–072602 – Part Number: 128377–07350

3 – Part Number: 196630–12980

196630-12980

(2)

(3)

WARNING

��

(1)


YM Series Operation Manual PRODUCT OVERVIEW

YANMAR YM FEATURES AND APPLICATIONSThe YM series are four-stroke direct injection diesel engines equipped with liquid coolant systems.

The 2YM15 is a 2-cylinder engine and is naturally aspirated.



These engines are equipped with a marine gear or sail drive unit.

These engines are designed for pleasure craft use and complied with EPA regulation Tier3 marine from 2009 year.

It is recommended that new vessels be propped so the engines can operate at 100 to 200 rpm above the Maximum Rated Power Output rpm (3700 to 3800) to allow for some added weight and hull resistance. The engine must be able to reach the Maximum Rated Power rpm (3600) under full load at all times.

Failure to do so can lead to reduced vessel performance, increased smoke levels and can cause permanent damage to your engine, which is not covered by warranty.

The engine must be installed correctly with coolant lines, exhaust gas lines and electrical wiring. Any auxiliary equipment attached to the engine should be easy to use and accessible for service. To handle the drive equipment, propulsion systems (including the propeller) and other onboard equipment, always observe the instructions and cautions given in the operation manuals supplied by the shipyard and equipment manufacturers.

The YM series engines are designed to be operated at maximum throttle (3600 rpm) for less than 5% of total engine time (30 minutes out of every 10 hours) and cruising speed (3400 rpm or less) for less than 90% of total engine time (9 hours out of every 10 hours).

The laws of some countries may require hull and engine inspections, depending on the use, size and cruising area of the boat. The installation, fitting and surveying of this engine all require specialized knowledge and engineering skills. See Yanmar’s local subsidiary in your region or your authorized Yanmar Marine dealer or distributor.

PRODUCT OVERVIEW


New Engine Break-InAs with all reciprocating engines, the way the engine is operated during its first 50 hours of operation plays a significant role in determining how long it will last and how well the engine will perform over its lifetime.

A new Yanmar diesel engine must be operated at suitable speeds and power settings during the break-in period to allow the sliding parts, such as piston rings, to break in properly and to stabilize engine combustion.

During the break-in period, the engine coolant temperature gauge should be monitored. The temperature should be between 71° and 87°C (160° and 190°F).

During the first 10 hours of operation, the engine should be operated at maximum rpm minus 400 to 500 rpm (approximately 60 to 70% of load) most of the time. This will ensure the sliding parts break in properly.

NOTICE: During this period, avoid operating at maximum engine speed and load to avoid damaging or scoring sliding parts.

Do not operate the engine at low idle or at low speed and light load for more than 30 minutes at a time. Since unburned fuel and engine oil will adhere to the piston rings when operating at low speeds for long periods, this will interfere with proper movement of the rings and the diesel fuel consumption may increase. Low idle speed does not allow break-in of sliding parts.

If operating the engine at low speed and light load, you must race the engine to clean the carbon from the cylinders and the fuel injection valve.

Perform this procedure in open waters:

• With the clutch in NEUTRAL, accelerate from the low-speed position to the high-speed position briefly.

• Repeat this process five times.

Once past the initial 10 hours until 50 hours, the engine should be used over its full operating range, with special emphasis on running at relatively high power settings. This is not the time for an extended cruise at idle or low speed. The boat should be operated at maximum speed minus 400 rpm most of the time (approximately 70% load), with a 10 minute run at maximum minus 200 rpm (approximately 80% load) every 30 minutes and a 4 to 5 minute period of operation at WOT (wide open throttle) once every 30 minutes. During this period, be sure not to operate the engine at low speed and light load for more than 30 minutes. If operating engine at low speed and light load is necessary, race the engine after low idle operation.

To complete engine break-in, perform After Initial 50 Hours maintenance procedures on page 56.

PRODUCT OVERVIEW


12/05


COMPONENT IDENTIFICATIONRight Side (from Flywheel) - 2YM15Figure 1 and Figure 2 illustrate a typical version of a 2YM15 engine. Your engine may have different equipment from that illustrated.

Figure 1

Figure 1

1 – Intake Silencer (air cleaner)2 – Intake Manifold3 – Fuel Filter4 – Fuel Injection Pump5 – Engine Oil Dipstick6 – Engine Oil Filler Cap7 – Fuel Feed Pump8 – Engine Oil Filter9 – Marine Gear

Left Side (from Flywheel) - 2YM15

Figure 2

Figure 2

1 – Seawater Pump2 – Coolant Filler Cap3 – Engine Nameplate (on rocker

arm cover)4 – Coolant Tank / Heat Exchanger5 – Exhaust Manifold6 – Starter Motor7 – Shift Lever8 – Alternator

(1)(2)

(3)

(4)

(5)

(6)

(7)(8)

(9)0004781

(1)

(2) (4)

(5)

(7)

(6)(8)

(3)

0004782

PRODUCT OVERVIEW


Right Side (from Flywheel) - 3YM20Figure 3 and Figure 4 illustrate a typical version of a 3YM20 engine. Your engine may have different equipment from that illustrated.

Figure 3

Figure 3



Figure 4

Figure 4



(1) (2)(3)

(4)

(5)(6)

(7)

(8)

(9) 0004783

(1)

(2) (3)

(4)

(5)

(6)

(7)(8)0004784

PRODUCT OVERVIEW


12/05


Right Side (from Flywheel) - 3YM30Figure 5 and Figure 6 illustrate a typical version of a 3YM30 engine. Your engine may have different equipment from that illustrated.

Figure 5

Figure 5



Figure 6

Figure 6



(1) (2)

(4)(5)(6)

(7)

(8)

(9)

(3)

0004785

(1)

(2) (3)

(4)

(5)(6)

(7)(8)0004786

PRODUCT OVERVIEW


LOCATION OF NAMEPLATESThe nameplate of the Yanmar YM series engine is shown in Figure 7. Check the engine’s model, output, rpm and serial number on the nameplate. Replace it if it is damaged or lost.

The engine nameplate is attached to the engine rocker arm cover.

Figure 7

Figure 7

The marine gear nameplate (Figure 8) is attached to the marine gear. Check the marine gear’s model, gear ratio, oil used, oil quantity and serial number.

Figure 8

Figure 8

/

/

Gear Model

ENG.No.

MFG. DATE

/

Model

min-1

min-1

min-1

Continuous power kW

Speed of prop. shaft

Fuel stop power kW

��

MODE L KMGEAR RATIOOIL SAE 20/30HDOIL QT Y. LTR.NO.

0004529

PRODUCT OVERVIEW


12/05


FUNCTION OF MAJOR COMPONENTS

Name of Component Function

Fuel Filter Removes dirt and water from the fuel. Drain the filter periodically. The filter element should be replaced periodically. The water separator (if equipped) should be drained periodically. See Draining Fuel Filter / Water Separator on page 60.

Fuel Feed Pump Pumps fuel from the tank to the fuel injection system. Pushing the manual lever on the side of the feed pump supplies fuel to the engine when fuel priming is needed.

Fuel Feed Lever Moving the fuel feed lever up and down feeds the fuel. The lever is used to bleed air from the fuel system after running out of fuel.

Engine Oil Filler Port Filler port for the engine oil.

Engine Oil Filter Filters fine metal fragments and carbon from the engine oil. Filtered engine oil is distributed to the engine’s moving parts. The filter is a spin-on type and the element should be replaced periodically. See Replacing the Engine Oil Filter Element on page 64.

Marine Gear Filler Port Filler port for marine gear oil; located on top of the marine gear case.

Cooling System There are two cooling systems: closed cooling with coolant (fresh water) and seawater. The engine is cooled by the closed cooling circuit. The closed circuit is cooled by seawater using a heat exchanger. The seawater also cools the engine / marine gear oil.

Closed Cooling Circulation Pump

The centrifugal water pump circulates coolant inside the engine. The circulating pump is driven by a V-belt.

Seawater Pump Pumps seawater from outside vessel to the engine. The seawater pump has a replaceable rubber impeller.

Coolant Filler Cap The filler cap on the heat exchanger / coolant tank covers the water supply port. The cap has a pressure regulating valve. When the cooling water temperature rises, the pressure rises inside the coolant system.

Coolant Recovery Tank The pressure valve in the filler cap releases vapor and hot water overflow to the coolant recovery tank. When the engine stops and the coolant cools, the pressure in the coolant tank drops. The filler cap vacuum valve then opens to send coolant back from the coolant recovery tank. This minimizes coolant consumption. The closed cooling system coolant level can easily be checked and refilled in this tank.

Engine Oil Cooler A heat exchanger that cools high temperature engine oil using coolant.

Intake Silencer (Air Cleaner) The intake silencer guards against dirt in the air and reduces the noise of air intake.

Nameplates Nameplates are provided on the engine and the marine gear and have the model, serial number and other data. See Location of Nameplates on page 14.

Starter Starter motor for the engine; powered by the battery.

Alternator Driven by a belt and generates electricity and charges the battery.

Engine Oil Dipstick Gauge stick for checking the engine oil level.

PRODUCT OVERVIEW


CONTROL EQUIPMENTThe control equipment at the helm makes remote control operation possible. It consists of the instrument panel, which is connected to the engine by a wire harness, and the remote control handle, which is connected by control cables to the engine control lever and marine gear.

Instrument Panel (Optional)

Equipment and Functions

The instrument panel is located at the helm. The following instruments enable you to start or stop the engine and to monitor its condition during operation. A typical instrument panel is shown in Figure 9.

Figure 9B-Type

Figure 9

1 – Tachometer2 – Hourmeter3 – Moisture Cap for Key Switch4 – Key Switch5 – STOP Button

6 – Battery Low Charge Indicator7 – Water in Sail Drive Seal

Indicator8 – Engine Oil Low Pressure

Indicator9 – Coolant High Temperature

Indicator

Gauges

B-Type panels use analog electric gauges with needle indicators.

0004486

(1)

(2)

(3)

(4)

(5)

(6)

(7)(8)

(9)

Instrument Function

Tachometer Shows the engine rotation speed.

Hourmeter Shows the number of operating hours; can be used as a guide for periodic maintenance checks. The hourmeter is located at the bottom of the tachometer.

Instrument Panel Lights When turning the key switch to ON, the gauges will illuminate for easier viewing.

PRODUCT OVERVIEW


12/05


Key Switch Figure 10

Figure 10

1 – GLOW2 – OFF3 – ON4 – START

The GLOW position (Figure 10, (1)) is the start aid position. Electric current to the glow plug is turned on. When the key is released, the switch will automatically move to the ON position.

The START position (Figure 10, (4)) allows current to the starting motor. When starting the engine, move the key to the START position and release. The key will automatically move to the ON position.

When the key is in the OFF position (Figure 10, (2)), the electric current is off. The key can be inserted or removed in this position.

The ON position (Figure 10, (3)) allows electrical current to the controls and equipment and allows the engine to keep running. To stop the engine, keep the key switch in the ON position and push the STOP button. After stopping the engine, turn the key to the OFF position.

0003622

(1)(2)

(3)

(4)

PRODUCT OVERVIEW


Figure 11B (Keyless) - Type (Optional)

Figure 11

1 – Coolant High Temperature Indicator

2 – Engine Oil Low Pressure Indicator

3 – Water in Sail Drive Seal Indicator

4 – Battery Low Charge Indicator

5 – OFF / ON / START Switch6 – STOP / GLOW Switch7 – Hourmeter8 – Tachometer

0

10

20 30

40

50

(8) (7) (5)(6)

(1) (2) (3) (4)

��

PRODUCT OVERVIEW


12/05


Indicators and Alarms (Optional)

When a sensor detects a problem during operation, the indicator on the instrument panel will light and an alarm will sound. Indicators are located on the instrument panel. The alarm is located on the back of the panel. Under normal operating conditions, the indicators are off.

Figure 12

Figure 12

Battery Low Charge Indicator (Figure 12) - When the alternator output is too low, the indicator will light. When charging begins, the indicator will turn off. No alarm will sound for low battery charge.

Figure 13

Figure 13

Coolant High Temperature Indicator and Alarm (Figure 13) - When coolant temperature reaches the maximum allowable temperature (95°C [203°F] or higher), the indicator will light and the alarm will sound. Continuing operation at temperatures exceeding the maximum limit will result in damage and seizure. Check the load and troubleshoot the cooling system.

Figure 14

Figure 14

Engine Oil Low Pressure Indicator and Alarm (Figure 14) - When the engine oil pressure falls below normal, the oil pressure sensor will send a signal to the indicator, causing it to light and the alarm to sound. Stop operation immediately to avoid damage to the engine. Check the oil level and troubleshoot the lubrication system.

Figure 15

Figure 15

Water in Sail Drive Seal Indicator and Alarm (Figure 15) - When seawater is detected between the seals of the sail drive, the indicator will light and the alarm will sound.

STOP Button Figure 16

Figure 16

Push the STOP button switch to stop the engine. The key switch must be in the ON position for the STOP button to operate. After the engine has come to a complete stop, you can turn the key to the OFF position.

0005439

PRODUCT OVERVIEW


AlarmsCheck that indicators and alarms are working normally when the key is turned to ON.

Single-Lever Remote Control Handle

Figure 17

Figure 17

1 – Low Speed - FWD or REV 2 – Low Speed - FWD or REV 3 – NEUTRAL - Power to the

propeller shaft is cut off and the engine idles

4 – Maximum Engine Speed - FWD or REV

5 – Maximum Engine Speed - FWD or REV

A single-lever handle type (Figure 17) should be used to operate the marine gear clutch (NEUTRAL, FORWARD, and REVERSE) and to control the engine speed.

The lever controls the direction of the boat (ahead or astern) and also acts as an accelerator by increasing engine speed as the lever is pushed further in the FORWARD or REVERSE directions.

When the lever is pulled out (Figure 18, (1)), the engine speed can be controlled without engaging the clutch. The clutch remains in the NEUTRAL, no load position. Turn the knob (Figure 18, (2)) counterclockwise to move the lever or clockwise to lock the lever.

Figure 18

Figure 18

Note: Yanmar recommends the use of a single-lever type for the remote control system. If only a two-lever type is available in the market, reduce engine rpm to 1000 or less before engaging and disengaging the marine gear clutch.

Key Switch OFF ⇒ ON START ⇒ ON

Engine Before start Running

Alarm Sound No sound

Indicators Battery Low Charge Indicator ON OFF

Coolant High Temperature Indicator OFF OFF

Engine Oil Low Pressure Indicator ON OFF

Water In Sail Drive Indicator OFF OFF

(1)

(4)

(3) (2)

(5)

0004504

(2)

(1)

0004511


YM Series Operation Manual BEFORE YOU OPERATE

SAFETY PRECAUTIONSBefore performing any operations within this section, review the Safety section on page 3.

INTRODUCTIONThis section of the Operation Manual describes the diesel fuel, engine oil and engine coolant specifications and how to replenish them.

BEFORE YOU OPERATE


DIESEL FUELDiesel Fuel SpecificationsWARNING! Fire and Explosion Hazard. Diesel fuel is flammable and explosive under certain conditions.

NOTICE: Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA warranty requirements. Only use clean diesel fuel.

Diesel fuel should comply with the following specifications. The table lists several worldwide specifications for diesel fuels.

Biodiesel Fuels

Yanmar approves the use of biodiesel fuels that do not exceed a blend of 5% non-mineral oil based fuel with 95% standard diesel fuel. Such biodiesel fuels are known in the marketplace as B5 biodiesel fuels. B5 biodiesel fuel can reduce particulate matter and the emission of “greenhouse” gases compared to standard diesel fuel.

NOTICE: If the B5 biodiesel fuel used does not meet the approved specifications, it will cause abnormal wear of injectors, reduce the life of the engine and it may affect the warranty coverage of your engine.

B5 diesel fuels must meet certain specifications.

The biodiesel fuels must meet the minimum specifications for the country in which they are used:

• In Europe, biodiesel fuels must comply with the European Standard EN14214.

• In the United States, biodiesel fuels must comply with the American Standard ASTM D-6751.

Biodiesel should be purchased only from recognized and authorized diesel fuel suppliers.

DIESEL FUELSPECIFICATION LOCATION

No. 2-D, No. 1-D, ASTM D975

USA

EN590:96 European Union

ISO 8217 DMX International

BS 2869-A1 or A2 United Kingdom

JIS K2204 Grade No. 2 Japan

BEFORE YOU OPERATE


12/05


Precautions and concerns regarding the use of biofuels:

• Biodiesel fuels have a higher content of methyl-esters, which may deteriorate certain metal, rubber and plastic components of the fuel system. The customer and / or boat builder are responsible to verify the usage of biodiesel compatible components on the vessel fuel supply and return systems.

• Free water in biodiesel may result in plugging of fuel filters and increased bacterial growth.

• High viscosity at low temperatures may result in fuel delivery problems, injection pump seizures, and poor injection nozzle spray atomization.

• Biodiesel may have adverse effects on some elastomers (seal materials) and may result in fuel leakage and dilution of the engine lubricating oil.

• Even biodiesel fuels that comply with a suitable standard as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks. It is important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system, and / or fuel storage containers, may be necessary.

• The use of biodiesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers, or biodiesel fuels that have degraded as per the precautions and concerns above, may affect the warranty coverage of your engine.

Additional Technical Fuel Requirements

• The fuel cetane number should be 45 or higher.

• The sulfur content must not exceed 0.5% by volume. Less than 0.05% is preferred.

• NEVER mix kerosene, used engine oil or residual fuels with the diesel fuel.

• Water and sediment in the fuel should not exceed 0.05% by volume.

• Keep the fuel tank and fuel-handling equipment clean at all times.

• Ash content should not exceed 0.01% by volume.

• Carbon residue content should not exceed 0.35% by volume. Less than 0.1% is preferred.

• Total aromatics content should not exceed 35% by volume. Less than 30% is preferred.

• PAH (polycyclic aromatic hydrocarbons) content should be below 10% by volume.

• NEVER use Biocide.

• NEVER use kerosene or residual fuels.

BEFORE YOU OPERATE


Handling of Diesel Fuel

WARNING! Fire and Explosion Hazard. Only fill the fuel tank with diesel fuel. Filling the fuel tank with gasoline may result in a fire and will damage the engine. NEVER refuel with the engine running. Wipe up all spills immediately. Keep sparks, open flames or any other form of ignition (match, cigarette, static electric source) well away when refueling.

WARNING! Fire and Explosion Hazard. ALWAYS put the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container. Hold the hose nozzle firmly against the side of the container while filling it. This prevents static electricity buildup which could cause sparks and ignite fuel vapors.

Fuel Tank (Optional)

NOTICE: Water and / or dust in the fuel may cause engine failure. When fuel is stored, check that the inside of the storage container is clean and dry, and that the fuel is stored away from dirt or rain.

Figure 1

Figure 1

1 – Sediment Bowl2 – Drain Cock3 – Fuel Line to Engine

Install a drain cock (Figure 1, (2)) at the bottom of the fuel tank to remove water and contaminants from the sediment bowl (Figure 1, (1)).

The fuel outlet should be positioned 20 to 30 mm (0.75 to 1.125 in.) above the bottom of the tank (Figure 2, (4)) so that only clean fuel is distributed to the engine.

0004542

(3)

(1) (2)

BEFORE YOU OPERATE


12/05


Fuel System Figure 2

Figure 2

1 – Fuel Filter2 – Fuel Feed Pump (priming lever)3 – Fuel / Water Separator

(optional)4 – Approximately 20 to 30 mm

(0.75 to 1.125 in.)5 – Within 500 mm (20 in.)6 – Drain Cock7 – Fuel Cock8 – Fuel Return Line9 – To Fuel Injection Pump

10 – Fuel Tank

Install the fuel line from the fuel tank to the fuel injection pump as shown in Figure 2. The recommended fuel / water separator (Figure 2, (3)) (optional) is installed at the center section of that line.

Filling the Fuel TankWARNING! Fire and Explosion Hazard. NEVER refuel with the engine running.

Before filling fuel tank for the first time:

Rinse the fuel tank with kerosene or diesel fuel. Dispose of waste properly.

To fill the fuel tank:

WARNING! Fire and Explosion Hazard. Operate bilge ventilation (blowers) for a minimum of 5 minutes to purge fumes from engine compartment after refueling. Never operate bilge blower while refueling. Doing so can pump explosive fumes into the engine compartment and result in an explosion.

1. Clean the area around the fuel cap.2. Remove the fuel cap from the fuel tank.3. Fill the tank with clean fuel free of oil

and dirt. WARNING! Fire and Explosion Hazard. Hold the hose nozzle firmly against the filler port while filling. This prevents static electricity buildup which could cause sparks and ignite fuel vapors.

4. Stop fueling when the gauge shows the fuel tank is full. WARNING! Fire and Explosion Hazard. NEVER overfill the fuel tank.

(1)

(2)(3)

(8)

(10)

(4)

(6)

(7)

(9)

(5)

0004788

BEFORE YOU OPERATE


5. Replace the fuel cap and hand-tighten. Over-tightening the fuel cap will damage it.

Figure 3

Figure 3

If filling the tank from a storage container (Figure 3), keep the fuel container stationary for several hours to allow any dirt or water to settle to the bottom of the container. Use a pump to extract the clear, filtered fuel from the top of the container.

Bleeding the Fuel SystemThe fuel system has an automatic air bleeding device that purges air from the fuel system. No manual air bleeding is required for normal operation. Manual bleeding must be done if any fuel system maintenance has been performed (replacement of fuel filter, etc.) or if the engine does not start after several attempts.

Bleeding the Fuel System Figure 4

Figure 4

1 – Air Bleed Screw2 – Bracket3 – O-Ring4 – Fuel Filter Element5 – Fuel Filter Housing6 – Retaining Ring

0004512

(1)

0004801

(2)

(3)

(4)

(5)

(6)

BEFORE YOU OPERATE


12/05


1. Check the fuel level in the fuel tank. Refill if necessary.

2. Open the fuel cock of the fuel tank. WARNING! Exposure Hazard. Always wear safety glasses when bleeding the fuel system.

3. Loosen the air bleed screw (Figure 4, (1)) 2 to 3 turns.

4. Push up and down on the manual priming lever located on the side of the fuel feed pump to release air out of the air bleed screw. Always use an approved container to catch the diesel fuel.

5. Continue pumping until a solid stream of fuel with no air bubbles begins to flow.

6. Tighten the air bleed screw.

Note: After engine start-up, the automatic air-bleeding device works to purge the air in the fuel system.

ENGINE OILEngine Oil Specifications NOTICE: Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal engine components to seize and / or shorten engine life. NEVER mix different types of engine oil. This may adversely affect the lubricating properties of the engine oil.

Use an engine oil that meets or exceeds the following guidelines and classifications:

• API Service Categories: CD or higher

TBN value: 9 or more

The oil must be changed when the Total Base Number (TBN) has been reduced to 2.0.

TBN (mgKOH/g) test method: JIS K-2501–5.2–2(HCI), ASTM D4739(HCI)

• Recommended SAE Viscosity: 10W30, 15W40. Engine oil 10W30 and 15W40 can be used throughout the year.

• NEVER use API Service Category CG-4 or CH-4 oils.

NOTICE:

1. Be sure the engine oil, engine oil storage containers and engine oil filling equipment are free of sediment or water.

2. Change the engine oil after the first 50 hours of operation and then at every 150 hours thereafter. See Changing the Engine Oil on page 57.

3. Select the oil viscosity based on the ambient temperature where the engine is being operated. See the SAE Service Grade Viscosity Chart (Figure 5).

4. Yanmar does not recommend the use of engine oil “additives.”

BEFORE YOU OPERATE


Handling Engine Oil

1. When handling and storing engine oil, be careful not to allow dust and water to contaminate the oil. Clean around the filler port before filling.

2. Do not mix lube oils of different types or brands. Mixing may cause the chemical characteristics of the oil to change and lubricating performance to decrease, reducing the engine’s life.

3. Engine oil should be replaced at the specified intervals, regardless of the engine’s operation history. See Periodic Maintenance Schedule on page 50.

Engine Oil Viscosity Figure 5

Figure 5

Select the appropriate engine oil viscosity based on the ambient temperature shown in the SAE Service Grade Viscosity Chart (Figure 5).

NOTICE: If you intend to operate your equipment at temperatures outside the limits shown, you must consult your authorized Yanmar Marine dealer or distributor for special lubricants or starting aids.

Checking the Engine Oil Figure 6

Figure 6

1 – Filler Port2 – Rocker Arm Cover3 – Dipstick4 – Upper Limit5 – Lower Limit

Note: 3YM30 shown. Other models are similar.

1. Make sure the engine is off. It is recommended that the engine be as level as possible before checking the oil.

2. NOTICE: Prevent dirt and debris from contaminating engine oil. Carefully clean the dipstick, filler port cap and the surrounding area before you remove the cap. Remove the dipstick (Figure 6, (3)) and wipe with a clean cloth.

3. Fully reinsert the dipstick.4. Remove the dipstick. The oil level

should be between upper (Figure 6, (4)) and lower (Figure 6, (5)) lines on the dipstick.

5. Add oil if necessary. See Adding Engine Oil on page 29.

6. Fully reinsert the dipstick.

-4°F 14°F 32°F 50°F 68°F 86°F 104°F (-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C)

SAE 10W-30

SAE 15W-40

0000005

(1)

(3)

(4)(5)

(2)

0004789

BEFORE YOU OPERATE


12/05


Adding Engine Oil1. NOTICE: Prevent dirt and debris from

contaminating engine oil. Carefully clean the dipstick, filler port cap and the surrounding area before you remove the cap. Remove the yellow oil filler port cap from the filler port (Figure 6, (1)) on the rocker arm cover (Figure 6, (2)) and fill with engine oil.

2. Fill with engine oil to the upper limit (Figure 6, (4)) on the dipstick (Figure 6, (3)). NOTICE: NEVER overfill the engine with engine oil.

3. Insert the dipstick fully to check the level. NOTICE: ALWAYS keep the oil level between the upper and lower lines on the oil cap / dipstick.

4. Hand-tighten the filler port cap securely.

MARINE GEAR OR SAIL DRIVE OILMarine Gear Oil SpecificationsUse marine gear oil that meets or exceeds the following guidelines and classifications:

KM2P-1 (S), (G) or (GG):

• API Service Categories: CD or higher

• SAE Viscosity: #20 or #30

Sail Drive Oil Specifications - SD20Refer to the Sail Drive Operation Manual for the procedure to fill or replace the sail drive oil.

SD20:

• API Service Category: GL4.5

• SAE Viscosity: 90 or 80W90

BEFORE YOU OPERATE


Checking Marine Gear Oil Figure 7

Figure 7

1 – Dipstick2 – Marine Gear Filler Port3 – Upper Limit4 – Lower Limit

1. Make sure the engine is off. Make sure the engine is as level as possible and wipe area clean around the marine gear filler port (Figure 7, (2)).

2. Remove the filler cap at the top of the housing.

3. Remove the dipstick (Figure 7, (1)) and wipe with a clean cloth.

4. Fully reinsert the dipstick.5. Remove the dipstick. The oil level

should be between the upper (Figure 7, (3)) and lower (Figure 7, (4)) lines on the dipstick.

6. Fully reinsert the dipstick.

Adding Marine Gear Oil1. Make sure the engine is as level as

possible.2. Remove the filler cap at the top of the

housing.3. Fill with oil to the upper limit on the

dipstick (Figure 7, (3)). See Marine Gear Oil Specifications on page 29. NOTICE: NEVER overfill the marine gear with oil.

4. Fully reinsert the dipstick.5. Hand-tighten the filler port cap.

Checking and Adding Sail Drive OilRefer to the Sail Drive Operation Manual for the procedure for checking and filling the sail drive oil.

(1)

(2)

0004811

(3)

(4)

BEFORE YOU OPERATE


12/05


ENGINE COOLANTEngine Coolant Specifications• Texaco Long Life Coolant (LLC), both

standard and premixed, product code 7997 and 7998

• Havoline Extended Life Antifreeze / Coolant, product code 7994

Note: In the U.S., LLC is required for the warranty to be valid.

NOTICE: Following the manufacturer’s recommendations, use a proper LLC which will not have any adverse effects on the materials (cast iron, aluminum, copper, etc.) of the engine’s cooling system. See Engine Coolant Specifications on page 31.

ALWAYS use the mixing ratios specified by the antifreeze manufacturer for the temperature range.

NOTICE: ALWAYS add LLC to soft water – especially when operating in cold weather. NEVER use hard water. Water should be clean and free from sludge or particles. Without LLC, cooling performance will decrease due to scale and rust in the coolant system. Water alone may freeze and form ice; it expands approximately 9% in volume. Use the proper amount of coolant concentrate for the ambient temperature as specified by the LLC manufacturer. LLC concentration should be a minimum of 30% to a maximum of 60%. Too much LLC will decrease the cooling efficiency. Excessive use of antifreeze also lowers the cooling efficiency of the engine. NEVER mix different types or brands of LLC, as a harmful sludge may form. Mixing different brands of antifreeze may cause chemical reactions, and may make the antifreeze useless or cause engine problems.

Replace the engine coolant periodically, according to the maintenance section in this Operation Manual.

Remove scale from the cooling system periodically by flushing the system.

Checking and Adding Coolant

Component identification Figure 8

Figure 8

1 – Coolant Tank / Heat Exchanger2 – Coolant Drain Plug3 – Seawater Drain Plug4 – Coolant Pump5 – Seawater Pump

Figure 9

Figure 9

1 – Coolant Tank / Heat Exchanger2 – Coolant Drain Plug3 – Seawater Drain Cock

(1)

(2)(3)

(5)

(4)

0004791

(1)

(2)(3)

0005576

BEFORE YOU OPERATE


Figure 10

Figure 10

1 – Stop Solenoid2 – Seawater Drain Plug3 – Flywheel Housing

Note: The drain cocks are opened before shipping from the factory. Close all drain cocks before filling the system with coolant.

1. Allow the engine to cool.2. Ensure all drain cocks are closed.3. Loosen the coolant tank filler cap to

relieve the pressure, then remove the filler cap. WARNING! Burn Hazard. NEVER remove the coolant filler cap if the engine is hot. Steam and hot engine coolant will spray out and seriously burn you. Allow the engine to cool down before you attempt to remove the cap.

Figure 11

1 – Filler Cap Tabs2 – Coolant Filler Cap3 – Filler Port Notches4 – Coolant Tank / Heat Exchanger

Figure 11

4. NOTICE: NEVER pour cold coolant into a hot engine.

Pour coolant slowly into the coolant tank / heat exchanger (Figure 11, (4)) to avoid air bubbles. Fill until coolant overflows from the filler port.

(1)

(2)(3)0004793

(2)

(1)

(4)(3) 0004492

BEFORE YOU OPERATE


12/05


5. Align the filler cap tabs (Figure 11, (1)) with filler port notches (Figure 11, (3)) and tighten the filler cap (Figure 11, (2)).

Figure 12

1 – Rubber Hose to Coolant Tank2 – FULL Mark3 – LOW Mark4 – Coolant Recovery Tank Cap

Figure 12

6. Check the coolant level in the coolant recovery tank. The level should be at the FULL mark (Figure 12, (2)). Add coolant if necessary.

Note: The coolant level rises in the coolant recovery tank during operation. After stopping the engine, the coolant will cool down and the extra coolant will return to the coolant tank.

Note: NOTICE: NEVER pour cold coolant into a hot engine.

7. Remove coolant recovery tank cap (Figure 12, (4)) to add coolant if necessary. NEVER add water.

8. Replace the filler cap and tighten it firmly. Failure to do so will cause coolant to leak.

WARNING! Burn Hazard. ALWAYS tighten the coolant tank cap securely after checking the coolant tank. Steam can spray out during engine operation if the cap is loose.

9. Check the rubber hose (Figure 12, (1)) connecting the coolant recovery tank to the coolant tank / heat exchanger. Replace if damaged.

NOTICE: If the coolant runs low too often or only the coolant level in the coolant tank / heat exchanger drops without any change in the level in the coolant recovery tank, there may be coolant or air leaks in the cooling system. See your authorized Yanmar Marine dealer or distributor.

LOW

FULL

((1)

(2)

(3)

0004493

Coolant Recovery Tank Capacity

0.8 L (0.95 qt)

BEFORE YOU OPERATE


CRANKING THE ENGINENOTICE: When performing engine break-in or if the engine has not been used for a long period of time, engine oil will not be distributed to all of the operating parts. Using the engine in this condition will lead to seizure.

After a long period of non-use, distribute engine oil to each part by cranking the engine. Perform the following procedure before beginning operation:

1. Open the seacock.2. Open the fuel cock.3. Put the remote control shift lever in

NEUTRAL.4. Turn the battery switch to ON (if

equipped). Figure 13


Figure 13

Note: If the engine has not been operated for a long period of time, check that the key moves smoothly from the START to ON positions.

5. Turn the key to ON (Figure 13, (3)).

6. While pushing the STOP button on the control panel, turn the key to the START position (Figure 13, (4)). NOTICE: NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat.

7. When the key is in the START position, the engine will begin cranking. Continue cranking for about 5 seconds and listen for abnormal noise during that time.

NOTICE: If the STOP button is released during the cranking procedure, the engine will start. NEVER start the engine in this mode.

0003622

(1)(2)

(3)

(4)


YM Series Operation Manual ENGINE OPERATION

SAFETY PRECAUTIONSBefore performing any operations within this section, read the following safety information and review the Safety section on page 3.

Fire and Explosion Hazard

NEVER jump-start the engine. Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion. ONLY use the key switch to

start the engine.

Sudden Movement HazardBe sure the boat is in open water away from other boats, docks or other obstructions before increasing rpm. Avoid unexpected equipment movement. Shift the marine gear into the NEUTRAL position any time the engine is at idle.

To prevent accidental equipment movement, NEVER start the engine in gear.

Sever HazardKeep children and pets away while the engine is operating.

ENGINE OPERATION


If any indicator illuminates during engine operation, stop the engine immediately. Determine the cause and repair the problem before continuing to operate the engine. If the alarm window with audible alarm fails to display and go out about 3 seconds later when the ignition switch is in the ON position, see your authorized Yanmar Marine dealer or distributor for service before operating the engine.

Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear:

• Avoid operating in extremelydusty conditions.

• Avoid operating in the presenceof chemical gases or fumes.

• NEVER run the engine if the am-bient temperature is above +40°C(+104°F) or below -16°C (+5°F).

• If the ambient temperature ex-ceeds +40°C (+104°F), the en-gine may overheat and cause theengine oil to break down.

• If the ambient temperature is be-low -16°C (+5°F), rubber compo-nents such as gaskets and sealswill harden, causing prematureengine wear and damage.

• Contact your authorized YanmarMarine engine dealer or distribu-tor if the engine will be operatedoutside of this standard tempera-ture range.

NEVER engage the starter motor while the engine is running. Damage to the starter motor pinion and / or ring gear will result.

INTRODUCTIONThis section of the Operation Manual describes the procedures for starting the engine, checking engine performance during operation and shutting down the engine.

ENGINE OPERATION


12/05


STARTING THE ENGINENOTICE: If the vessel is equipped with a water lift (water lock) muffler, excessive cranking could cause seawater to enter the cylinders and damage the engine. If the engine does not start after cranking for 10 seconds, close the seacock to avoid filling the muffler with water. Crank for 10 seconds or until the engine starts. When the engine does start, stop the engine immediately and turn the switch to the OFF position.

1. Open the seacock (if equipped).2. Open the fuel cock.3. Put the remote control handle in

NEUTRAL.

Note: Safety equipment should make it impossible to start the engine in any position other than NEUTRAL.

Figure 1


Figure 1

4. Turn the battery master switch (if equipped) to ON.

5. Turn key switch to ON (Figure 1, (3)). Ensure that the instrument panel indicators light and the alarm sounds. This indicates that indicators and alarm are working correctly.

Note: The coolant high temperature alarm indicator and water in sail drive seal indicator should not come on during start-up.

6. Turn key switch to START (Figure 1, (4)). Release the key switch when the engine has started. NOTICE: NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat.

7. The alarm should stop and the indicators should go out. NOTICE: If any indicator fails to illuminate when the key switch is in the ON position, see your authorized Yanmar Marine dealer or distributor for service before operating the engine.

Note: When the engine has not been used for a long period of time, check that the key moves smoothly from the START position to the ON position.

Restarting After Starting FailureBefore turning the key switch again, be sure the engine has stopped completely. NEVER attempt to restart the engine while the engine is running. The pinion gear on the starter motor will be damaged. NOTICE: NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat.

NOTICE: NEVER attempt to restart the engine if the engine has not stopped completely. Pinion gear and starter motor damage will occur.

Air Bleeding the Fuel System After Starting Failure

If the engine does not start after several attempts, there may be air in the fuel system. If air is in the fuel system, fuel cannot reach the fuel injection pump. Bleed the air out of the system. See Bleeding the Fuel System on page 26.

0003622

(1)(2)

(3)

(4)

ENGINE OPERATION


Starting at Low TemperaturesComply with local environmental requirements. Use engine heaters to avoid starting problems and white smoke. NOTICE: NEVER use an engine starting aid such as ether. Engine damage will result. Using a starting aid may void the warranty.

To limit white smoke, run the engine at low speed and under moderate load until the engine reaches normal operating temperature. A light load on a cold engine provides better combustion and faster engine warm-up than no load.

Avoid running the engine at idling speed any longer than necessary.

Starting with Air Heater (If Equipped)

1. Open the seacock (if equipped).2. Open the fuel tank cock.3. Put remote control handle in

NEUTRAL.4. Turn the battery master switch (if

equipped) to ON.5. Turn key switch to GLOW for 15

seconds.6. Turn key switch to ON. Ensure that the

instrument panel indicators light and the alarm sounds. This shows that indicators and alarm are working correctly.

Note: The coolant high temperature alarm indicator and water in sail drive seal indicator should not come on during start-up.

7. Turn key switch to START. Release the key switch when the engine has started. The alarm should stop and the indicators should go out. NOTICE: NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat.

After the Engine has StartedAfter the engine has started, check the following items at a low engine speed:

1. Check that the gauges, indicators and alarm are normal.

2. Check for any water, fuel, engine coolant or engine oil leaks. If any leaks are found, shut down the engine and perform the necessary repairs.WARNING! Piercing Hazard. NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar Marine dealer or distributor repair the damage. Avoid skin contact with the high-pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line. High-pressure fuel can penetrate your skin and result in serious injury. If you are exposed to high-pressure fuel spray, obtain prompt medical treatment.

3. Check that the exhaust color, engine vibration and sound are normal.

4. When there are no problems, keep the engine at low speed with the boat still stopped to distribute engine oil to all parts of the engine.

ENGINE OPERATION


12/05


Check that water is being discharged from the seawater outlet pipe. Operation with inadequate seawater discharge will damage the impeller of the seawater pump. If seawater discharge is too low, stop the engine immediately. Identify the cause and repair. NOTICE: The engine will seize if it is operated when cooling seawater discharge is inadequate or if load is applied without any warm-up operation.

When operating the engine at low speed for long periods of time, race the engine once every 2 hours. Race the engine with the clutch in NEUTRAL, accelerate from the low-speed position to the high-speed position and repeat this process about five times. This cleans out carbon from the cylinders and the fuel injection valves. NOTICE: Neglecting to race the engine will result in poor exhaust color and reduce engine performance.

Periodically operate the engine near maximum speed while underway. This will generate higher exhaust temperatures, which will help clean out hard carbon deposits, maintain engine performance and prolong the life of the engine.

For troubleshooting assistance, see Troubleshooting After Starting on page 69 or see Troubleshooting Chart on page 71.

If necessary, see your authorized Yanmar Marine dealer or distributor.

REMOTE CONTROL HANDLE OPERATIONAcceleration and Deceleration

Figure 2

Figure 2

1 – FORWARD or REVERSE2 – NEUTRAL3 – REVERSE or FORWARD4 – Throttle Handle / Clutch Handle

Note: Direction of travel will vary depending on installation location.

Use the throttle handle (Figure 2, (4)) to control acceleration and deceleration. Move the handle slowly.

0004513

(1)

(2)

(4)

(3)

ENGINE OPERATION


Shifting the EngineWARNING! Sudden Movement Hazard. The boat will start to move when the marine gear is engaged:

• Ensure the boat is clear of all obstacles forward and aft.

• Quickly shift to the FORWARD position then back to the NEUTRAL position.

• Observe whether the boat moves in the direction you expect.

NOTICE: Shifting the marine gear while operating at high speed or not pushing the handle fully into position (partial engagement) will result in damage to marine gear parts and abnormal wear.

• Before using the marine gear, be sure to move the throttle handle to a low idle position (less than 1000 rpm). Move the throttle handle slowly to a higher speed position after completing clutch engagement.

• NOTICE: NEVER shift the marine gear at high engine speed. During normal operation, the marine gear should only be shifted with the engine at idle. When moving the handle between FORWARD (Figure 2, (1 or 3)) and REVERSE (Figure 2, (1 or 3)), bring the clutch to NEUTRAL (Figure 2, (2)) and pause before slowly shifting to the desired position. Do not shift abruptly from FORWARD to REVERSE or vice versa.

• NOTICE: When sailing, set the remote control lever in NEUTRAL. Not doing so WILL introduce slippage or any damage and void your warranty.

SHUTTING DOWN THE ENGINENOTICE: NEVER stop engine abruptly during operation. Yanmar recommends that when shutting the engine down, allow the engine to run, without load, for 5 minutes. This will allow the engine components that operate at high temperatures, such as the exhaust system, to cool slightly before the engine is shut down.

1. Reduce engine speed to low idle and put remote control handle in NEUTRAL.

2. Accelerate from low speed to high speed and repeat five times. This will clean out the carbon from the cylinders and the fuel injection nozzles.

3. Allow engine to run at low speed (approximately 1000 rpm) without load for 5 minutes. NOTICE: Continue to hold the STOP button in until the engine is completely stopped. If the button is released before the engine has completely stopped, it may restart. If the engine does not shut down, see Emergency Shutdown on page 41 .

ENGINE OPERATION


12/05


4. With the key in the ON position, push and hold the STOP button (Figure 3, (1)). After the engine has stopped, turn the key switch to OFF.

Note: Continue to hold the STOP button in until the engine is completely stopped. If the button is released before the engine has completely stopped, it may restart. If the engine does not shut down, see Emergency Shutdown on page 41 .

Figure 3

1 – STOP ButtonFigure 3

5. Remove the key and cover the key switch with the moisture cap.

6. Turn off the battery master switch (if equipped).

7. Close the fuel cock.8. Close the seacock (if equipped).

NOTICE: ALWAYS close the seacock. Neglecting to close the seacock could allow water to leak into the boat and may cause it to sink.

Emergency ShutdownNOTICE: NEVER use the emergency stop switch for a normal engine shutdown. Use this switch only when stopping the engine suddenly in an emergency.

If the engine cannot be shut down by the STOP button on the panel, stop the engine by pushing the STOP button (Figure 4, (1)) at the back of the stop solenoid (Figure 4, (2)).

Figure 4

Figure 4

1 – STOP Button2 – Stop Solenoid

0004487

(1)

(1)

(2) 0004787

ENGINE OPERATION


CHECKING THE ENGINE AFTER OPERATION• Check that the key switch is in the OFF

position and that the battery master switch (if equipped) is turned to OFF.

• Fill the fuel tank. See Filling the Fuel Tank on page 25.

• Close seacock(s).

• If there is a risk of freezing, check that the cooling system contains enough coolant. See Engine Coolant Specifications on page 31.

• If there is a risk of freezing (temperatures below 0°C [32°F]), drain the seawater system (see Draining the Cooling System on page 76) and connect the engine heater (if equipped).


YM Series Operation ManualPERIODIC MAINTENANCE

SAFETY PRECAUTIONSBefore performing any maintenance procedures within this section, read the following safety information and review the Safety section on page 3.

Crush HazardIf the engine needs to be transported for repair, have a helper assist you in attaching it to a hoist and loading it on a truck.

The engine lifting eyes are engineered to lift the weight of the marine engine only. ALWAYS use the engine lifting eyes when lifting the engine.

Additional equipment is necessary to lift the marine engine and marine gear together. ALWAYS use lifting equipment with sufficient capacity to lift the marine engine.

Explosion HazardALWAYS turn off the battery switch (if equipped) or disconnect the negative (-) battery cable before servicing the equipment.

Entanglement Hazard NEVER leave the key in the key switch when you are servicing the engine. Someone may accidentally start the engine and not realize you are servicing it.

Stop the engine before you begin to service it.

Piercing HazardAvoid skin contact with high-pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line.

High-pressure fuel can penetrate your skin and result in serious injury. If you are exposed to high-pressure fuel spray, obtain prompt medical treatment.

NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar Marine dealer or distributor repair the damage.

PERIODIC MAINTENANCE


Tool HazardALWAYS remove any tools or shop rags used during maintenance from the area before operation.

Shock HazardALWAYS turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the equipment.

ALWAYS keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors.

Welding HazardMake welding repairs safely.

• ALWAYS turn off the battery switch (if equipped) or disconnect the negative battery cable and the leads to the alternator when welding on the equipment.

• Remove the multi-pin connector to the engine control unit. Connect the weld clamp to the component to be welded and as close as possible to the welding point.

• NEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket.

• When welding is completed, reconnect the leads to the alternator and engine control unit prior to reconnecting the batteries.

Any part which is found defective as a result of inspection, or any part whose measured value does not satisfy the standard or limit, must be replaced.

Modifications may impair the engine’s safety and performance characteristics and shorten the engine’s life. Any alterations to this engine may void its warranty. Always use Yanmar genuine replacement parts.



12/05


INTRODUCTIONThis section of the Operation Manual describes the procedures for proper care and maintenance of the engine.

PRECAUTIONSThe Importance of Periodic MaintenanceEngine deterioration and wear occur in proportion to the length of time the engine has been in service and the conditions the engine is subjected to during operation. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor engine performance and helps extend the life of the engine.

Performing Periodic MaintenanceWARNING! Exhaust Hazard. NEVER block windows, vents, or other means of ventilation if the engine is operating in an enclosed area. All internal combustion engines create carbon monoxide gas during operation. Accumulation of this gas within an enclosure could cause illness or even death. Make sure that all connections are tightened to specifications after repair is made to the exhaust system. Failure to comply could result in death or serious injury.

The Importance of Daily ChecksThe Periodic Maintenance Schedule assumes that the daily checks are performed on a regular basis. Make a habit of performing daily checks before the start of each operating day. See Daily Checks on page 55.



Keep a Log of Engine Hours and Daily ChecksKeep a log of the number of hours the engine is operated each day and a log of the daily checks performed. Also note the date, type of repair (e.g., replaced alternator) and parts used for any service needed between the periodic maintenance intervals. Periodic maintenance intervals are every 50, 100, 150, 250 and 1000 engine hours. NOTICE: Failure to perform periodic maintenance will shorten the life of the engine and may void the warranty.

Yanmar Replacement PartsYanmar recommends that using genuine Yanmar parts when replacement parts are needed. Genuine replacement parts help ensure long engine life.

Tools RequiredBefore starting any periodic maintenance procedure, make sure you have the tools needed to perform all of the required tasks.

Ask Your Authorized Yanmar Marine Dealer or Distributor for HelpOur professional service technicians have the expertise and skills to help with any maintenance or service related procedures.



12/05


Tightening FastenersUse the correct amount of torque when you tighten fasteners on the engine. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure.

NOTICE: The tightening torque in the Standard Torque Chart should be applied only to the bolts with a “7” head (JIS strength classification: 7T). Apply 60% torque to bolts that are not listed. Apply 80% torque when tightened to aluminum alloy.

Standard Torque Chart

Bolt Diameter x Pitch (mm) M6x1.0 M8x1.25 M10x1.5 M12x1.75 M14x1.5 M16x1.5

Tightening Torque

N·m 11.0 ± 1.0 26.0 ± 3.0 50.0 ± 5.0 90.0 ± 10.0 140.0 ± 10.0 230.0 ± 10.0

kgf·m 1.1 ± 0.1 2.7 ± 0.3 5.1 ± 0.5 9.2 ± 1.0 14.3 ± 1.0 23.5 ± 1.0

lb-ft 8.0 ± 0.7 19.0 ± 2.1 37 ± 3.6 66.0 ± 7.2 103 ± 7.2 170 ± 7.2



EPA MAINTENANCE REQUIREMENTSTo maintain optimum engine performance and compliance with the Environmental Protection Agency (EPA) Regulations for Engines, it is essential to follow the Periodic Maintenance Schedule on page 50 and the Periodic Maintenance Procedures on page 55.

EPA Requirements for USA and Other Applicable CountriesThe following are the requirements for the EPA. Unless these requirements are met, the exhaust gas emissions will not be within the limits specified by the EPA.

The EPA emission regulation is applicable only in the USA and other countries that have adopted the EPA requirements in part or in whole. Determine and follow the emission regulations in the country where your engine will be operating to assist you in specified compliance.

Conditions to Ensure Compliance with EPA Emission StandardsThe 2YM15, 3YM20 and 3YM30 are EPA-certified engines.

The following are the conditions that must be met in order to ensure that the emissions during operation meet the EPA standards:

• Ambient temperature: -20° to +40°C (-4° to +104°F)

• Relative humidity: 80% or lower

The diesel fuel should be:

• ASTM D975 No. 1-D or No. 2-D, or equivalent (minimum of cetane No. 45)

The lubricating oil should be:

• Type API, Class CD or higher

Perform the inspections as outlined in Periodic Maintenance Procedures on page 55 and keep a record of the results.

Pay particular attention to these important points:

• Replacing the engine oil

• Replacing the engine oil filter

• Replacing the fuel filter

• Cleaning the intake silencer (air cleaner)

Note: Inspections are divided into two sections in accordance with who is responsible for performing the inspection: the user or the manufacturer.

Inspection and MaintenanceSee Inspection and Maintenance of EPA Emission-Related Parts on page 54 for the EPA emission-related parts. Inspection and maintenance procedures not shown in the Inspection and Maintenance of EPA Emission-Related Parts section are covered in Periodic Maintenance Schedule on page 50.

This maintenance must be performed to keep the emission values of the engine within the standard values during the warranty period. The warranty period is determined by the age of the engine or the number of hours of operation.

Installing Sample PortAll engines subject to emission standards shall be equipped with a connection in the engine exhaust system that is located downstream of the engine, and before any point at which the exhaust contacts water (or any other cooling / scrubbing medium), for the temporary attachment of gaseous and / or particulate emissions sampling equipment.



12/05


This connection shall be internally threaded with standard pipe threads of a size not larger than 12.7 mm (0.5 in.), and shall be closed by a pipe plug when not in use. Equivalent connections are allowed.

The instructions for the proper installation and location of the required sample port, in addition to those specified above in the quoted federal regulation, are as follows:

1. The connection should be located as far downstream as reasonably practicable from any sharp bend (of 30° or more) in the exhaust pipe to help ensure that a well-mixed exhaust flow sample may be taken;

2. The requirement that the connection be located before any point at which the exhaust contacts water (or any other cooling/scrubbing medium) does not include contact with water used to cool exhaust manifolds, unless the water is allowed to come into direct contact with the exhaust gases;

3. To allow ready access to the sample port, the connection should be located, if possible given the constraints of vessel design, approximately 0.6 to 1.8 m (2 to 6 ft) above a deck or walkway;

4. To facilitate insertion and withdrawal of an exhaust sample probe, there should be no obstructions for at least one and one-half exhaust pipe/stack diameters perpendicular, i.e., 90°, from the sample port; and

5. If a threaded connection is used, both the internal and external threads should be coated with a high-temperature, anti-seize compound before the initial installation and at every subsequent re-installation to facilitate removal of the connection for testing.



PERIODIC MAINTENANCE SCHEDULEDaily and periodic maintenance is important to keep the engine in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary depending on engine application, loads, diesel fuel and engine oil used and are hard to establish definitively. The following should be treated only as a general guideline. NOTICE: Establish a periodic maintenance plan according to the engine application and make sure to perform the required periodic maintenance at the intervals indicated. Failure to follow these guidelines will impair the engine’s safety and performance characteristics, shorten the engine’s life and may affect the warranty coverage on your engine. See your authorized Yanmar Marine dealer or distributor for assistance when checking items marked with a ●.



12/05


: Check or Clean : Replace ●: Contact your authorized Yanmar Marine dealer or distributor

System Item

Periodic Maintenance Interval

Before Starting

See Daily Checks

on page 38.

Initial 50

Hours

Every 50

hours or

monthly which-

ever comes

first

Every 100

hours or six

months which-

ever comes

first

Every 150

hours or one year

whichever

comes first

Every 250

hours or one year

whichever

comes first

Every 1000

hours or 4

years which-

ever comes

first

Whole Visual inspection of engine exterior

Fuel System

Check the fuel level and refill if necessary

Drain water and sediment from the fuel tank

Drain the fuel / water separator

Replace the fuel filter element

Check the fuel injection timing

●

Check the fuel injector spray pattern*

●*

Lubricating System

Check the engine oil level

Engine

Marine Gear

Replace the engine oil

Engine

Marine Gear

Sail Drive

Replace the oil filter element

Engine



Cooling System

Seawater outlet During

Operation

Check coolant level

Check or replace the seawater pump impeller

Replace coolant Every year. When Long Life Coolant (LLC) is used, replace every two years. See Engine Coolant Specifications on page 33.

Clean and check the seawater passages

●

Air Intake and Exhaust System

Clean the intake silencer (air cleaner) element

Clean or replace the exhaust / water mixing elbow

Clean the breather pipe

Check the exhaust gas condition

During

Operation

Check diaphragm assembly

●

Electrical System

Check the alarm and indicators

Check the electrolyte level in the battery

Adjust the tension of the alternator V-belt or replace V-belt

Check the wiring connectors


System Item


Before Starting

See Daily Checks

on page 38.

Initial 50

Hours

Every 50

hours or

monthly which-

ever comes

first

Every 100

hours or six

months which-

ever comes

first

Every 150

hours or one year

whichever

comes first

Every 250

hours or one year

whichever

comes first

Every 1000

hours or 4

years which-

ever comes

first



12/05


* For EPA requirements, see Inspection and Maintenance of EPA Emission-Related Parts on page 54.

Note: These procedures are considered normal maintenance and are performed at the owner’s expense.

Engine Cylinder Head and Block

Check for leakage of fuel, engine oil and engine coolant

After

Starting

Tighten all major nuts and bolts

●

Adjust intake / exhaust valve clearance

●

Miscellane- ous Items

Check the remote control cables

●

Adjust the propeller shaft alignment

●


System Item


Before Starting

See Daily Checks

on page 38.

Initial 50

Hours

Every 50

hours or

monthly which-

ever comes

first

Every 100

hours or six

months which-

ever comes

first

Every 150

hours or one year

whichever

comes first

Every 250

hours or one year

whichever

comes first

Every 1000

hours or 4

years which-

ever comes

first



Inspection and Maintenance of EPA Emission-Related Parts• Marine diesel engines less than 37 kW (50 hp) are certified as EPA non-road engine

• Marine diesel engines greater than 37 kW (50 hp) are certified as EPA CI marine engines

Inspection and Maintenance of EPA Emission-Related Parts for Non-Road and CI Marine Engines

Note: The inspection and maintenance items shown above should be performed at your Yanmar Marine dealer or distributor.

Parts Interval

Clean the fuel injection nozzle. 1500 hours

Check the fuel injection nozzle pressure and spray pattern. 3000 hours

Check the fuel injection pump adjustment.

Check turbocharger adjustment (if equipped).

Check the electronic engine control unit and its associated sensors and actuators (if equipped).



12/05


PERIODIC MAINTENANCE PROCEDURESWARNING! Exposure Hazard. ALWAYS wear personal protective equipment when performing periodic maintenance procedures.

Daily ChecksBefore you start for the day, make sure the engine is in good operating condition. NOTICE: It is important to perform the daily checks as listed in this Operation Manual. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor engine performance and helps extend the life of the engine.

Make sure to check the following items:

Visual Checks

1. Check for engine oil leaks.2. Check for fuel leaks.

WARNING! Piercing Hazard. Avoid skin contact with the high-pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line. High-pressure fuel can penetrate your skin and result in serious injury. If you are exposed to high-pressure fuel spray, obtain prompt medical treatment. NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar Marine dealer or distributor repair any damage.

3. Check for engine coolant leaks.4. Check for damaged or missing parts.5. Check for loose, missing or damaged

fasteners.6. Check the electrical harnesses for

cracks, abrasions, and damaged or corroded connectors.

7. Check hoses for cracks, abrasions and damaged, loose or corroded clamps.

8. Check the fuel filter / water separator for presence of water and contaminants. If any water or contaminants are found, drain the fuel filter / water separator. See Draining Fuel Filter / Water Separator on page 60. If you have to drain the fuel filter / water separator frequently, drain the fuel tank and check for water in your fuel supply. See Draining the Fuel Tank on page 63.

NOTICE: If any problem is noted during the visual check, the necessary corrective action should be taken before operating the engine.

Checking Diesel Fuel, Engine Oil and Engine Coolant Levels

Follow the procedures in Filling the Fuel Tank on page 25, Checking the Engine Oil on page 28 and Checking and Adding Coolant on page 31 to check these levels.

Checking and Refilling Marine Gear Oil

See Checking Marine Gear Oil on page 30.

Checking the Battery Electrolyte Level

Check the battery electrolyte level before use. See Checking the Battery Electrolyte Level (Serviceable Batteries Only) on page 61.

Checking the Alternator Belt

Check the belt tension before use. See Checking and Adjusting the Alternator V-Belt Tension on page 58.



Checking the Remote Control Handle

Check the operation of the remote control handle and ensure it moves smoothly. If it is hard to operate, grease the joints of the remote control cable and lever bearings. If the lever is too loose, adjust the remote control cable. See Checking and Adjusting the Remote Control Cables on page 59.

Checking the Alarm Indicators

Check the instruments and alarm indicators at regular intervals.

Preparing Fuel, Oil and Coolant in Reserve

Prepare sufficient diesel fuel for the day’s operation. Always store engine oil and coolant in reserve (for at least one refill) onboard, to be ready for emergencies.

Perform the following maintenance after the initial 50 hours of operation.

• Draining the Fuel Tank

• Changing the Engine Oil

• Replacing the Engine Oil Filter Element

• Changing the Marine Gear Oil

• Checking and Adjusting the Alternator V-Belt Tension

• Inspecting and Adjusting Intake / Exhaust Valve Clearance

• Checking and Adjusting the Remote Control Cables

• Adjusting Propeller Shaft Alignment

After Initial 50 Hours of Operation



12/05


Draining the Fuel Tank

WARNING! Fire and Explosion Hazard. When you are draining the fuel tank to perform maintenance, put an approved container under the opening to catch the fuel. NEVER use a shop rag to catch the fuel. Vapors from the rag are flammable and explosive. Wipe up any spills immediately.

WARNING! Exposure Hazard. Wear eye protection. The fuel system is under pressure and fuel could spray out when you remove any fuel system component.

Figure 1

Figure 1

1 – Sediment Bowl2 – Drain Cock3 – Fuel Line to Engine

Note: Optional fuel tank shown. Actual equipment may be different.

1. Put a pan under the drain cock (Figure 1, (2)) to catch fuel.

2. Open the drain cock and drain water and sediment. Close the drain cock when the fuel is clean and free of air bubbles.

Changing the Engine Oil

The engine oil on a new engine becomes contaminated from the initial break-in of internal parts. It is very important that the initial oil replacement is performed as scheduled.

It is easiest and most effective to drain the engine oil after operation while the engine is still warm. WARNING! Burn Hazard. If the engine oil must be drained while it is still hot, stay clear of the hot engine oil to avoid being burned. ALWAYS wear eye protection.

1. Turn the engine off.2. NOTICE: Prevent dirt and debris from

contaminating engine oil. Carefully clean the dipstick and the surrounding area before removing the dipstick. Remove the engine oil dipstick. Attach the oil drain pump (if equipped) and pump out the oil. For easier draining, remove the engine oil fill cap.

3. Fill with new engine oil. See Adding Engine Oil on page 29. NOTICE: NEVER mix different types of engine oil. This may adversely affect the lubricating properties of the engine oil. NEVER overfill. Overfilling may result in white exhaust smoke, engine overspeed or internal damage.

4. Perform a trial run and check for oil leaks.

5. Approximately 10 minutes after stopping the engine, remove the oil dipstick and check the oil level. Add oil if the level is too low.

0004542

(3)

(1) (2)



Replacing the Engine Oil Filter Element

1. Turn the engine off.2. Turn the engine oil filter Figure 2

counterclockwise with a wrench.3. Remove the engine oil filter.

Figure 2

Figure 2

Note: 3YM20 shown.

4. Install a new filter element and hand-tighten until the seal touches the housing.

5. Turn filter an additional 3/4 turn using a box wrench. Tighten to 20 to 24 N·m (177 to 212 lb-in.).


Changing the Marine Gear Oil

Note: Refer to the Marine Gear Operation Manual for procedure.

During initial operation, the oil is quickly contaminated due to the initial wear of internal parts. The marine gear oil must therefore be replaced early.

1. Remove cap from the filler port and attach an oil drain pump. Drain marine gear oil.

2. Fill marine gear with clean marine gear oil. See Marine Gear Oil Specifications on page 29.


4. Approximately 10 minutes after stopping the engine, remove the oil dipstick and check the oil level. Add oil if the level is too low.

Checking and Adjusting the Alternator V-Belt Tension

NOTICE: NEVER get any oil on the belt(s). Oil on the belt causes slipping and stretching. Replace the belt if it is damaged.

WARNING! Sever Hazard. Perform this check with engine off and key removed to avoid contact with moving parts.

Figure 3

Figure 3

1 – Middle of V-Belt2 – Alternator Bolt3 – V-Pulley (coolant pump)

Note: 3YM20 shown.

1. Remove the belt cover.2. Check the belt by pushing on the

middle of the belt (Figure 3, (1)) with your finger.With proper tension, the belt should deflect 8 to 10 mm (approximately 3/8 in.).

0004797

0004800

(1)

(2)

(3)



12/05


3. Loosen the alternator bolt (Figure 3, (2)) and move the alternator to adjust the V-belt tension.

4. Install the belt cover.

Note: If replacing the V-belt, loosen the V-pulley (Figure 3, (3)) of the coolant pump to remove the V-belt.

Inspecting and Adjusting Intake / Exhaust Valve Clearance

Proper adjustment is necessary to maintain the correct timing for opening and closing the valves. Improper adjustment will cause the engine to run noisily, resulting in poor engine performance and engine damage. See your authorized Yanmar Marine dealer or distributor to adjust the intake / exhaust valve clearance.

Checking and Adjusting the Remote Control Cables

NOTICE: Never adjust the high-speed stop bolt (Figure 4, (4)) on the governor. This will void the engine warranty.

The various control levers on the engine side are connected to the remote control lever by remote control cables. The cables will become stretched and the attachments loose after long hours of operation. It is dangerous to control operation under these conditions, and the remote control cables must be checked and adjusted periodically.

Adjusting the Throttle Remote Control Cable

Figure 4

Figure 4

1 – Cable2 – Fuel Injection Pump3 – Adjustment4 – High-Speed Stop Bolt5 – Low-Speed Stop Bolt6 – Control Lever

1. Check that the control lever on the engine side moves to the high-speed stop position and low-speed stop position when the remote control lever is moved to H (high speed) and L (low speed) respectively.

2. When there is deviation, loosen the bracket for the remote control cable on the engine side and adjust.

3. Adjust the high-speed stop position first and then adjust the low-speed idling using the adjustment bolt on the remote control lever.

(1)

(2)

(3)

(4)

(5)(6)

0004798



Adjusting Clutch Remote Control Cable Figure 5

Figure 5

1 – Marine Gear2 – Control Cable3 – Control Lever4 – Bracket (cable)

1. Check that the control lever (Figure 5, (3)) moves to the correct position when the remote control cable handle is moved to the NEUTRAL, FORWARD and REVERSE positions.

2. Use the NEUTRAL position as the standard for adjustment. When there is deviation, loosen the bracket (Figure 5, (4)) for the remote control cable on the clutch side and adjust.

Adjusting Propeller Shaft Alignment

The flexible engine mounts are compressed slightly during initial engine operation and may cause misalignment between the engine and the propeller shaft.

After the first 50 hours of operation, the alignment should be checked and readjusted if necessary. This is considered normal maintenance and the adjustment requires specialized knowledge and techniques. Consult your authorized Yanmar Marine dealer or distributor.

When completing the initial 50 hour maintenance procedures, perform the following procedures every 50 hours thereafter or monthly, whichever comes first.

• Draining Fuel Filter / Water Separator

• Checking the Battery Electrolyte Level

Draining Fuel Filter / Water Separator

WARNING! Fire and Explosion Hazard. When removing any fuel system component to perform maintenance (such as changing the fuel filter), put an approved container under the opening to catch the fuel. NEVER use a shop rag to catch the fuel. Vapors from the rag are flammable and explosive. Wipe up any spills immediately.

WARNING! Exposure Hazard. Wear eye protection. The fuel system is under pressure and fuel could spray out when removing any fuel system component.

(1)

(3) 0004799

(2)(4)

Every 50 Hours of Operation



12/05


Figure 6

Figure 6

1 – Air Bleed Screw2 – Bracket3 – O-Ring4 – Fuel Filter Element5 – Fuel Filter Housing6 – Retaining Ring

1. Close the fuel cock of the fuel tank.2. Put a pan under the fuel / water

separator.3. Loosen the retaining ring

(Figure 6, (6)), remove the filter housing (Figure 6, (5)) and drain off any water or sediment collected inside.

4. After draining, tighten the air bleed screw (Figure 6, (1)).

5. Be sure to bleed air from the fuel system. See Bleeding the Fuel System on page 26.

Checking the Battery Electrolyte Level (Serviceable Batteries Only)

NEVER operate with insufficient battery electrolyte. Operating with insufficient electrolyte will destroy the battery.

WARNING! Exposure Hazard. Batteries contain sulfuric acid. NEVER allow battery fluid to come in contact with clothing, skin or eyes. Severe burns could result. ALWAYS wear safety goggles and protective clothing when servicing the battery. If battery fluid contacts the eyes and / or skin, immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment.

NOTICE: NEVER turn off the battery switch (if equipped) or short the battery cables during operation. Damage to the electrical system will result.

NOTICE: Battery fluid tends to evaporate in high temperatures, especially in summer. In such conditions, inspect the battery earlier than specified.

1. Make sure the engine is off and the key is removed.

2. Turn the battery master switch to OFF (if equipped) or disconnect the negative (-) battery cable.

3. Remove the plugs and check the electrolyte level in all cells. NOTICE: NEVER attempt to remove the covers or fill a maintenance-free battery.

(1)

0004801

(2)

(3)

(4)

(5)

(6)



4. If the electrolyte level is lower than the minimum fill level (Figure 7, (1)), fill with distilled water (Figure 7, (2)) (available locally) up to the upper limit (Figure 7, (3)) of the battery.

Figure 7

Figure 7

1 – Lower Level2 – Distilled Water3 – Upper Level

Note: The maximum fill level is approximately 10 to 15 mm (3/8 to 9/16 in.) above the plates.

Perform the following maintenance every 100 hours or every 6 months of operation, whichever comes first.

• Changing the Sail Drive Gear Oil

Changing the Sail Drive Gear Oil

Refer to the Sail Drive Operation Manual for the procedure for changing gear oil.

UPPER LEVEL LOWER LEVEL

(2)

(3)

(1)

0004566




12/05


Perform the following maintenance every 150 hours or every year of operation, whichever comes first.

• Changing the Engine Oil

Changing the Engine Oil

See Changing the Engine Oil on page 57.

Perform the following maintenance every 250 hours or 1 year of operation, whichever comes first.

• Draining the Fuel Tank

• Replacing the Fuel Filter Element

• Replacing the Engine Oil Filter Element

• Changing the Marine Gear Oil

• Checking or Replacing the Seawater Pump Impeller

• Replacing the Coolant

• Cleaning the Intake Silencer (Air Cleaner) Element

• Cleaning or Replacing the Exhaust / Water Mixing Elbow

• Adjusting the Alternator V-Belt Tension

• Cleaning the Breather Pipe

• Checking the Wiring Connectors

Draining the Fuel Tank

See Draining the Fuel Tank on page 57.

Every 150 Hours of Operation Every 250 Hours of Operation



Replacing the Fuel Filter Element

WARNING! Fire and Explosion Hazard. When removing any fuel system component to perform maintenance (such as changing the fuel filter), put an approved container under the opening to catch the fuel. NEVER use a shop rag to catch the fuel. Vapors from the rag are flammable and explosive. Wipe up any spills immediately.

WARNING! Exposure Hazard. Wear eye protection. The fuel system is under pressure and fuel could spray out when removing any fuel system component.

Figure 8

Figure 8

1 – Housing2 – Retaining Ring

When there is dirt in the fuel, the filter becomes clogged and the fuel will not flow easily. Check and replace the element.

1. Close the fuel cock of the fuel tank.2. Place an approved container under the

fuel filter.3. Remove the filter case by loosening the

retaining ring (Figure 8, (2)). Turn the ring counterclockwise using a filter wrench.

4. Remove the housing (Figure 8, (1)) and remove the element. Replace the element with a new one.

5. Apply a thin film of clean diesel fuel to the sealing surface of the new filter gasket.

6. Clean the inside of the housing thoroughly, install the O-ring and hand-tighten the retainer ring. Use a filter wrench and tighten to 12 N·m (106 in.-lb).

7. Air will enter the fuel system when the filter is disassembled. Bleed the fuel system to remove any air from the system. See Bleeding the Fuel System on page 26.

8. Dispose of waste properly.

Replacing the Engine Oil Filter ElementSee Replacing the Engine Oil Filter Element on page 58.

Changing the Marine Gear OilSee Changing the Marine Gear Oil on page 58.

Checking or Replacing the Seawater Pump Impeller1. Loosen side cover bolts and remove

the side cover.2. Inspect the inside of the seawater

pump with a flashlight. If any of the following are found, service the seawater pump:• Impeller blades are cracked or nicked.

Edges or surfaces of the blades are marred or scratched.

• Wear plate is damaged.3. If no damage is found when inspecting

the inside of the pump, install the O-ring and side cover.

4. If a large amount of water leaks continuously from the water drain line below the seawater pump during operation, replace the mechanical seal. See your authorized Yanmar Marine dealer or distributor.

When disassembly and maintenance of the seawater pump are necessary, consult your Yanmar Marine dealer or distributor.

(1)

0004804

(2)



12/05


The seawater pump turns in the direction as shown in Figure 9. The impeller must be installed while considering the impeller direction.

Figure 9

Figure 9

1 – Impeller Vane Direction2 – Impeller Rotating Direction3 – Impeller4 – Seawater Pump

Replacing the Coolant

CAUTION! Coolant Hazard. Wear eye protection and rubber gloves when you handle engine coolant. If contact with the eyes or skin should occur, flush eyes and wash immediately with clean water.

Replace coolant every year.

Note: If Long Life Coolant (LLC) is used, replace coolant every 2 years.


1. Put a pan under the coolant drain cocks.

2. Open all coolant drain cocks.3. Allow to drain completely. Dispose of

waste properly.4. Close all the drain cocks.5. Fill coolant tank and coolant recovery

tank with appropriate coolant. See Engine Oil Specifications on page 27 and see Checking and Adding Coolant on page 31.

Cleaning the Intake Silencer (Air Cleaner) Element

1. Disassemble the intake silencer (air cleaner).

2. Remove element (Figure 10, (1)). Clean element and housing with a neutral detergent.

3. Dry completely and reassemble. Figure 10

Figure 10

4) (3)

(1)

(2)

0004806

(1)

0004805



Cleaning or Replacing the Exhaust / Water Mixing Elbow

There are two types of mixing elbows, the L-type and the U-type. The mixing elbow is attached to the exhaust manifold. The exhaust gas is mixed with seawater in the mixing elbow.

1. Remove the mixing elbow.2. Clean dirt and scale out of the exhaust

and seawater passages.3. If the mixing elbow is damaged, repair

or replace it. See your authorized Yanmar Marine dealer or distributor.

4. Inspect the gasket and replace if necessary.

Replace the mixing elbow with a new one every 500 hours or 2 years, whichever comes first, even if no damage is found.

See your authorized Yanmar Marine dealer or distributor.

Adjusting the Alternator V-Belt Tension

See Checking and Adjusting the Alternator V-Belt Tension on page 58.

Cleaning the Breather Pipe


Checking the Wiring Connectors


Perform the following maintenance every 1000 hours or 4 years of operation, whichever comes first.

• Checking the Fuel Injection Timing

• Checking the Fuel Injector Spray Pattern

• Replacing the Seawater Pump Impeller

• Cleaning and Checking the Seawater Passages

• Checking the Diaphragm Assembly

• Replacing the Alternator V-Belt

• Adjusting Intake / Exhaust Valve Clearance

• Checking and Adjusting the Remote Control Cables

• Adjusting the Propeller Shaft Alignment

• Tightening All Major Nuts and Bolts




12/05


Checking the Fuel Injection Timing


Checking the Fuel Injector Spray Pattern


Replacing the Seawater Pump Impeller

The seawater impeller must be replaced every 1000 hours or every 4 years even if it is not damaged.

See Checking or Replacing the Seawater Pump Impeller on page 64.

Cleaning and Checking the Seawater Passages

After prolonged use, clean the seawater passages to remove dirt, scale, rust and other contaminants that collect in the coolant passages. This can cause poor engine cooling. Inspect these items:

• Heat Exchanger

• Pressure Cap


Checking the Diaphragm Assembly

Inspect the diaphragm assembly on the rocker arm cover.

1. Loosen screws and remove diaphragm assembly.

2. Check for oil and contaminants between the diaphragm and cover. NOTICE: If oil and contaminants enter the diaphragm assembly, the diaphragm will not operate properly.

3. Inspect the diaphragm rubber and spring for damage. If necessary, replace with new ones.

Figure 11Breather System Components

Figure 11

1 – Diaphragm Cover2 – Spring3 – Center Plate4 – Diaphragm5 – Rocker Arm Cover6 – Breather Baffle7 – Baffle Plate8 – Intake Silencer (air cleaner)

(5)

(6)

(7)(8) 0004807

(1)(2)(3)(4)



Replacing the Alternator V-Belt

1. Remove the V-belt cover.2. Loosen the V-belt tension adjusting bolt

of the alternator.3. Remove the alternator V-belt.4. Install a new alternator V-belt.5. Adjust the alternator V-belt tension.


6. Replace the V-belt cover.

Adjusting Intake / Exhaust Valve Clearance


Checking and Adjusting the Remote Control Cables

See Checking and Adjusting the Remote Control Cables on page 59.

Adjusting the Propeller Shaft Alignment


Tightening All Major Nuts and Bolts

See Tightening Fasteners on page 47 or see your authorized Yanmar Marine dealer or distributor.


YM Series Operation Manual TROUBLESHOOTING

SAFETY PRECAUTIONSBefore performing any troubleshooting procedures within this section, review the Safety section on page 3.

If a problem occurs, stop the engine immediately. Refer to the Symptom column in the Troubleshooting Chart to identify the problem.

TROUBLESHOOTING AFTER STARTINGJust after the engine has started, check the following items at a low engine speed:

Is sufficient water being discharged from the seawater outlet pipe?

If the discharge is low, stop the engine immediately. Identify the cause and repair.

Is the exhaust color normal?

The continuous emission of black exhaust smoke indicates engine overloading. This shortens the engine’s life and should be avoided. When operating the engine at low speed for long periods of time, race the engine once every 2 hours. Racing the engine with the clutch in NEUTRAL, accelerate from the low-speed position to the high-speed position and repeat this process about five times. This is done to clean out carbon from the cylinders and the fuel injection valves. NOTICE: Neglecting to race the engine will result in poor exhaust color and reduce engine performance.

Periodically operate the engine near maximum speed while underway. This will generate higher exhaust temperatures, which will help clean out hard carbon deposits, maintain engine performance and prolong the life of the engine.

TROUBLESHOOTING


Are there abnormal vibrations or noise?

Depending on the hull structure, engine and hull resonance may suddenly increase at certain engine speed ranges, causing heavy vibrations. Avoid operation in this speed range. If any abnormal sounds are heard, stop the engine and inspect for cause.

Alarm sounds during operation.

If the alarm sounds during operation, lower the engine speed immediately, check the warning lamps and stop the engine for repairs.

Is there water, oil or fuel leakage? Are there any loose bolts or connections?

Check the engine room daily for any leaks or loose connections.

Is there sufficient fuel in the fuel tank?

Refill fuel in advance to avoid running out of fuel. If the tank runs out of fuel, bleed the fuel system. See Bleeding the Fuel System on page 26.

Troubleshooting InformationIf the engine does not operate properly, refer to the Troubleshooting Chart on page 71 or see your authorized Yanmar Marine dealer or distributor.

Supply your authorized Yanmar Marine dealer or distributor with the following information:

• Model name and serial number of your engine

• Boat model, hull material, size (tons)

• Use, type of boating, number of hours run

• Total number of operation hours (refer to hourmeter) and age of boat

• The operating conditions when the problem occurs:

• Engine rpm• Color of exhaust smoke• Type of diesel fuel• Type of engine oil• Any abnormal noises or vibration• Operating environment such as high

altitude or extreme ambient temperatures, etc.

• Engine maintenance history and previous problems

• Other factors that contribute to the problem

TROUBLESHOOTING


12/05


TROUBLESHOOTING CHART

Symptom Probable Cause Measure Reference

Indicators light on the instrument panel and alarm sounds during operation

Shift to low-speed operation immediately, and check which indicator has come on. Stop the engine and inspect. If no abnormality is identified and there is no problem with operation, return to port at lowest speed and see your authorized Yanmar Marine dealer or distributor.

Engine oil low pressure alarm indicator lights

Engine oil level is low. Check engine oil level. Add or replace as necessary.

See Checking the Engine Oil on page 28.

Engine oil filter is clogged. Replace engine oil filter. Replace engine oil.

See Changing the Engine Oil on page 57.

Water in sail drive seal indicator lights

Rubber sail drive seal is broken. See your authorized Yanmar Marine dealer or distributor.

-

Coolant high temperature alarm lights

Coolant in coolant tank / heat exchanger is low.

Check coolant level and refill.

See Checking and Adding Coolant on page 31.

Insufficient seawater level causing temperature to rise.

Check seawater system. -

Contamination inside cooling system.


-

Faulty Warning Devices Do not operate the engine if alarm devices are not repaired. See you authorized Yanmar Marine dealer or distributor. Serious accidents may result if abnormalities are not identified due to faulty indicators or alarm.

Indicators Do Not Light:When key is turned onWhen any trouble occurs (low oil pressure, etc.)

No electrical current available. Circuit broken or lamp burned out.


-

One of the indicators does not go out

Sensor switch is faulty. See your authorized Yanmar Marine dealer or distributor.

-

• Battery low charge indicator does not go out during operation

V-belt is loose or broken. Replace V-belt or adjust tension.


Battery is defective. Check battery fluid level, specific gravity or replace battery.

See Checking the Battery Electrolyte Level (Serviceable Batteries Only) on page 61.

Alternator power generation failure.


-

TROUBLESHOOTING


Starting Failures:

• Starter turns but engine does not start

No fuel. Add fuel. Bleed fuel system.

See Filling the Fuel Tank on page 25 and see Bleeding the Fuel System on page 26.

Fuel filter is clogged. Replace filter element. See Replacing the Fuel Filter Element on page 64.

Improper fuel. Replace with recommended fuel.

See Diesel Fuel Specifications on page 22.

Problem with fuel injection. See your authorized Yanmar Marine dealer or distributor.

-

Compression leakage from intake / exhaust valve.


-

• Starter does not turn or turns slowly (engine can be turned manually)

Faulty clutch position. Shift to NEUTRAL and start.

See Restarting After Starting Failure on page 37.

Insufficient battery charge. Check fluid level. Recharge or replace battery.

See Checking the Battery Electrolyte Level (Serviceable Batteries Only) on page 61.

Cable terminal contact failure. Remove corrosion from terminals. Tighten battery cables.

-

Faulty safety switch device. See your authorized Yanmar Marine dealer or distributor.

-

Faulty starter switch. See your authorized Yanmar Marine dealer or distributor.

-

Power lacking due to accessory drive being engaged.


-

• Engine cannot be turned manually

Internal parts seized. See your authorized Yanmar Marine dealer or distributor.

-


TROUBLESHOOTING


12/05


Abnormal Exhaust Color:

• Black smoke Load increased. See your authorized Yanmar Marine dealer or distributor.

-

Improper propeller matching. See your authorized Yanmar Marine dealer or distributor.

-

Dirty intake silencer (air cleaner). Clean element. See Cleaning the Intake Silencer (Air Cleaner) Element on page 65.

Improper fuel. Replace with recommended fuel.


Faulty spraying of fuel injector. See your authorized Yanmar Marine dealer or distributor.

-

Incorrect intake / exhaust valve clearance.


-

• White smoke Improper fuel. Replace with recommended fuel.


Faulty spraying of fuel injector. See your authorized Yanmar Marine dealer or distributor.

-

Fuel injection timing off. See your authorized Yanmar Marine dealer or distributor.

-

Excessive diesel fuel consumption.


-


TROUBLESHOOTING


This Page Intentionally Left Blank


YM Series Operation Manual LONG-TERM STORAGE

SAFETY PRECAUTIONSBefore performing any storage procedures within this section, review the Safety section on page 3.

INTRODUCTIONIf the engine will not be used for an extended period of time, special measures should be taken to protect the cooling system, fuel system and combustion chamber from corrosion and the exterior from rusting.

The engine can normally stand idle for up to 6 months. If it remains unused for longer than this, please contact your authorized Yanmar Marine dealer or distributor.

LONG-TERM STORAGE


PREPARE ENGINE FOR LONG-TERM STORAGENote: If the engine is close to a periodic maintenance interval, perform those maintenance procedures before putting the engine into long-term storage.

1. Wipe off any dust or oil from the outside of engine.

2. Drain water from the fuel filters.3. Drain the fuel tank completely or fill the

tank to prevent condensation.4. Drain the Cooling System (see Draining

the Cooling System on page 76).5. Grease the exposed areas and joints of

the remote control cables and the bearings of the remote control handle.

6. Seal the intake silencer, exhaust pipe, etc. to prevent moisture or contamination from entering engine.

7. Completely drain the bilge in hull bottom.

8. Waterproof the engine room to prevent rain or seawater from entering.

9. Charge the battery once a month to compensate for battery’s self-discharge.

10.Remove the key from key switch and cover the key switch with moisture cap.

DRAINING THE COOLING SYSTEM

Figure 1

Figure 1

1 – Alternator2 – Coolant Tank / Heat Exchanger3 – Coolant Drain Cock4 – Seawater Drain Cock

Figure 2

Figure 2

1 – Coolant Tank / Heat Exchanger2 – Seawater Drain Cock3 – Coolant Drain Cock4 – Coolant Pump5 – Seawater Pump

(1)(2)

(3)

(4)0004794

(1)

(2)(3)

(5)

(4)

0004795

LONG-TERM STORAGE


12/05


Figure 3

Figure 3

1 – Stop Solenoid2 – Coolant Drain Cock3 – Flywheel Housing


NOTICE: If seawater is left inside, it may freeze and damage parts of the cooling system (heat exchanger, seawater pump, etc.) when ambient temperature is below 0°C (32°F).

1. Put a pan under the seawater drain cocks.

2. Open the seawater drain cocks on the pipe and on the heat exchanger. Allow to drain.

3. Remove the four bolts fastening the side cover of the seawater pump. Remove the cover and drain the seawater.

4. Install the cover and tighten bolts.5. Close all drain cocks.

NOTICE: NEVER drain engine coolant in the cold season or before long storage. If LLC (Long Life Coolant) has not been added to the cooling system, add LLC or drain the coolant from the coolant system after daily use. If the coolant without LLC is not removed, it may freeze and damage parts of the cooling system or engine when ambient temperature is below 0°C (32°F).

(1)

(2)(3)0004793

LONG-TERM STORAGE




YM Series Operation Manual SPECIFICATIONS

PRINCIPAL ENGINE SPECIFICATIONS2YM15 Engine Specifications

Specification 2YM15

Marine Gear Model KM2P-1 SD-20

Use Pleasure use

Type Vertical water cooled 4-cycle diesel engine

Combustion System Swirl pre-combustion chamber

Air Charging Natural aspiration

Number of Cylinders 2

Bore x Stroke 70 mm x 74 mm (2.76 in. x 2.92 in.)

Displacement 0.570 L (35.0 cu in.)

Continuous Rated Output

Output at Crankshaft / Engine Speed

9.4 kW (12.8 hp metric) / 3489 rpm*

Maximum Rated Output


10.3 kW (14.0 hp metric) / 3600 rpm*10.0 kW (13.6 hp metric) / 3600 rpm**

Output at Propeller / Engine Speed

10.0 kW (13.6 hp metric) / 3600 rpm* 9.7 kW (13.2 hp metric) / 3600 rpm**

-

Installation Flexible mounting

Fuel Injection Timing FID 21 ±1° BTDC

Fuel Injection Opening Pressure 12.3 to 13.28 MPa (125 to 135 kgf/cm2)

Main Power Take Off At flywheel end

Direction of Rotation

Crankshaft Counterclockwise viewed from stern

Propeller Shaft (Ahead)

Clockwise viewed from stern -

Cooling System Closed coolant system with heat exchanger

Lubrication System Complete enclosed forced lubrication system

Coolant Capacity Engine 3.0 L (3.17 qt), Coolant recovery tank: 0.8 L (0.95 qt)

SPECIFICATIONS


Note: Density of fuel: 0.842 g/cm3 at 15°C. Fuel temperature at the inlet of the fuel injection pump. 1hp metric = 0.7355 kW

Lubricating Oil Capacity (Engine)

Rake Angle at rake angle 8° at rake angle 0°

Total*** 2.0 L (2.1 qt) 1.8 L (1.9 qt)

Effective**** 0.95 L (1.0 qt) 0.9 L (0.95 qt)

Starting System

Type Electric

Starting Motor DC 12 V - 1.4 kW

AC Alternator 12 V - 60 A (12 V - 80 A optional)

Engine Dimension

Overall Length 613 mm (24.1 in.) -

Overall Width 463 mm (18.2 in.)

Overall Height 528 mm (20.8 in.)

Engine Dry Mass (Including Marine Gear)

115 kg (253 lb) 134 kg (295 lb)

* Rating Condition: Temperature of fuel; 25°C at fuel pump inlet; ISO 3046-1

** Rating Condition: Temperature of fuel; 40°C at fuel pump inlet; ISO 8665

*** The “total” oil quantity includes oil in oil pan, channels, coolers and filter.

**** The effective amount of oil shows the difference in maximum scale of the dipstick and minimum scale.

Specification 2YM15


SPECIFICATIONS


12/05


3YM20 Engine Specifications

Specification 3YM20


Use Pleasure use









14.7 kW (20.0 hp metric) / 3489 rpm*




Output atPropeller / Engine Speed


-


Fuel Injection Timing FID 22 ± 1° BTDC












Total*** 2.7 L (2.85 qt) 2.4 L (2.54 qt)


Starting System

Type Electric



SPECIFICATIONS



Engine Dimension





130 kg (287 lb) 151 kg (333 lb)





Specification 3YM20


SPECIFICATIONS


12/05


3YM30 Engine Specifications

Specification 3YM30


Use Pleasure use









20.1 kW (30.0 hp metric) / 3600 rpm*




Output atPropeller / Engine Speed


-


Fuel Injection Timing FID 16 ±1° BTDC












Total*** 2.8 L (2.96 qt) 2.5 L (2.64 qt)


Starting System

Type Electric



SPECIFICATIONS



Engine Dimension





133 kg (293 lb) 154 kg (339 lb)





Specification 3YM30


SPECIFICATIONS


12/05


Marine Gear and Sail Drive Specifications

Model KM2P-1(S) KM2P-1(G) KM2P-1(GG) SD20 (coupled at boat builder)

Type Mechanical cone clutch Dog Clutch

Reduction Ratio (Forward / Reverse)

2.21 / 3.06 2.62 / 3.06 3.22 / 3.06 2.64 / 2.64

Propeller Speed (Forward / Reverse) *

1580 / 1140 rpm

1332 / 1140 rpm

1083 / 1140 rpm 1322 rpm

Lubrication System Splash Oil bath

Lubricating Oil Capacity (Total)0.3 L (0.32 qt)

2.2 L (2.3 qt) Standard2.5 L (2.6 qt)

Long Reach

Lubricating Oil Capacity (Effective)

0.05 L (0.05 qt) - 0.15 L (0.16 qt) -

Cooling System Air cooling by fan on flywheel -

Weight 10.3 kg (27.7 lb) 30 kg (66.1 lb)

* At continuous power engine speed 2907 rpm

SPECIFICATIONS




YM Series Operation Manual SYSTEM DIAGRAMS

PIPING DIAGRAMSPiping diagrams and wiring diagrams are provided for reference only. Contact your authorized Yanmar Marine dealer or distributor for the most current diagrams.

Notes:

1. Steel pipe shows OD x wall thickness, rubber hose shows ID x wall thickness.

2. Rubber fuel lines meet EN/ISO7840.3. Unit: mm

Notation DescriptionScrew Joint (Union)

Flange Joint

Eye Joint

Insertion Joint

Drilled Hole

Coolant Piping

Seawater Piping

Engine Oil Piping

Diesel Fuel Piping

SYSTEM DIAGRAMS


Figure 12YM15 with KM2P-1 Marine Gear

Figure 1

P

P

P

P

T

(1) (2)

(3) (4)

(5) (6)

(7)

(8) (9) (10)

(11)

(12)

(13)

(15)

(14)

(16)

(17)

(18)

(19)(20)(21)(22)

(24)

(25)

(26)

(23)

(27)

(28)

(29)

(30)

(31)

(32)

(33)

(34)

(36)

(38)(37)

(35)

C

D

��

��

��

B

A

SYSTEM DIAGRAMS


12/05


Unit: mm (in.) 1 – 7.8 x t4.5 Rubber Hose2 – Check Valve3 – 7.8 x t4.5 Rubber Hose4 – 7.8 x t4.5 Rubber Hose5 – Overflow6 – Fuel Inlet7 – 7.8 x t4.5 Rubber Hose8 – 5 x t4.5 Rubber Hose9 – 7.8 x t4.5 Rubber Hose

10 – Fuel Feel Pump11 – Fuel Injection Pump12 – 4.76 x t0.7 Steel Pipe13 – Engine Oil Filter (cartridge

type)14 – 4.76 x t0.7 Steel Pipe15 – Fuel High-Pressure Pipe16 – Fuel Injection Nozzle17 – Oil Pressure Switch18 – Mixing Elbow19 – 17 x 14 Rubber Hose20 – Heat Exchanger21 – Engine Oil Inlet Filter22 – Main Bearing23 – Seawater Inlet24 – 17 x t4 Rubber Hose25 – Seawater Pump26 – 28 x t4 Rubber Hose27 – 28 x t4 Rubber Hose28 – Hot Water Connection Outlet

(R3/8)29 – Thermostat30 – Coolant Pump31 – Hot Water Connection Inlet

(R3/8)32 – Coolant Temperature Switch33 – Engine Oil Pump34 – Pressure Control Valve35 – Diesel Fuel36 – To Oil Pan37 – To Camshaft38 – From Cylinder Head

Detail of part A Detail of part B

Detail of part C Detail of part D

Ø17(0.67)

18(0

.71)

��

Ø50

(1.9

7)

��

Ø8 (0.31)

Ø9 (0.35)

17 (0

.67)

��

Ø8.5 (0.33)

Ø8 (0.31)16

.5(0

.65)

��

SYSTEM DIAGRAMS


Figure 23YM20 and 3YM30 with KM2P-1 Marine Gear

Figure 2

P

P

P T

P

��

��

��

(1) (2) (3)

(4)(5)

(6)

(7)(8)

(9)

(11)

(10)

(12)

(13)(14)

(15)

(16)

(17)

(18)

(19)

(20)

(21)

(22)(23)

B

A

C

D

SYSTEM DIAGRAMS


12/05


Unit: mm (in.) 1 – PCV2 – Overflow3 – Fuel Inlet4 – Fuel Feed Pump5 – Fuel Injection Pump6 – Engine Oil Filter (cartridge

type)7 – Fuel High-Pressure Pipe8 – Fuel Injection Nozzle9 – Oil Pressure Switch

10 – Mixing Elbow11 – Heat Exchanger12 – Engine Oil Inlet Filter13 – Main Bearing14 – Seawater Inlet15 – Seawater Pump16 – Hot Water Connection Outlet17 – Thermostat18 – Coolant Pump19 – Hot Water Connection Inlet20 – Coolant Temperature Switch21 – Engine Oil Pump22 – Pressure Control Valve23 – Fuel Filter24 – To Oil Pan25 – To Camshaft26 – From Cylinder Head

Detail of part A Detail of part B

Detail of part C Detail of part D

Ø17(0.67)

18(0

.71)

��

Ø50

(1.9

7)

��

Ø8 (0.31)

Ø9 (0.35)

17 (0

.67)

��

Ø8.5 (0.33)

Ø8 (0.31)16

.5(0

.65)

��

SYSTEM DIAGRAMS



SYSTEM DIAGRAMS


12/05


WIRING DIAGRAMS

Color Coding

R Red

B Black

W White

L Blue

RB Red / Black

LB Blue / Black

YW Yellow / White

YG Yellow / Green

WL White / Blue

WG White / Green

GR Green / Red

O Orange

WBr White / Brown

Allowable Length by Cross Sectional Area of Battery Cable

Section of Cable mm2 (in.2)

Allowable Length L = 1 + 2 + 3 m (ft)

15 (0.023) < 0.86 (0.26)

20 (0.031) < 1.3 (0.40)

30 (0.046) < 2.3 (0.70)

40 (0.062) < 2.8 (0.85)

50 (0.077) < 3.5 (1.07)

60 (0.093) < 4.1 (1.25)

SYSTEM DIAGRAMS


Figure 32YM15, 3YM20, 3YM30 - B-Type Instrument Panel

Figure 3

-+

S

B LE

3R

0.85LB0.85RB

0.85

YW

0.85

WL

0.85

O0.

85Y

G

R

2L

12V

1

3

2

10R10

B

0.85

B

2B

2R WB

r

2B 5R

+ -

W/Y

B3B

R

B

Y

+-B L YG RB

2W

17

G1

+-P

G2

30

WB

r

AC

R LL

R

W

O

B

YW

WL

YG

LB

2B2B

5R

2W

2B

0.85B

1289

90-7

7910

1192

47-7

7100

1202

70-7

7511

1197

17-7

7800

0.85WBr

2R

A A3R

3WYW

WL

WG

BRB

LBO

YG

GLO

WO

FFO

NS

TAR

T

30A

CG

1G

217

3L

��

(9)

(8)

(7)

(10)

(12)

(13)

(15)

(14)

(16)

(18)

(17)

(21)

(19)

(20)

(22)

(23)

(24)

(25)

(26)

(27)

(28)

(29)

(30)

(11)

(3)

(2)

(6)

(5)

(4)

(1)

SYSTEM DIAGRAMS


12/05


1 – Alarm Lamps2 – Buzzer Oil Pressure3 – Coolant Temperature4 – Sail Drive Seal5 – Charge6 – Fuse (3A)7 – Stop Switch8 – Diodes9 – Key Switch

10 – Tachometer Hour Meter11 – Instrument Panel12 – Wire Harness Option L=3M13 – Wire Harness Option L=6M14 – Amplifier Only for Sail Drive15 – Procured by Customer

16 – Battery17 – Battery Switch18 – Engine Stop Solenoid19 – Relay20 – Glow Plug21 – Stop Relay22 – Starter Relay23 – Starter24 – Coolant Temperature Switch25 – Engine Oil Pressure Switch26 – Alternator27 – Ground28 – Sail Drive (only for sail drive)29 – Key Switch30 – Coupler (view from A-A)

SYSTEM DIAGRAMS


Figure 42YM15, 3YM20, 3YM30 - B (Keyless) - Type Instrument Panel (Optional)

Figure 4

��

(18)

(19)

(25)

(26)

(30)

(29) (31)

(32)

(20)

(28)

(27)

(24)

(17)

(13)

(14)

(15)

(16)

(7)

(8)

(6)

(5)

(4)

(3)

(2)

(1)

(9)

(10)

(11)

(12)

(12)

(22)

(21)

(23)

-+

S

B LE

3R

0.85LB0.85RB

0.85

YW

0.85

WL

0.85

O0.

85Y

G

R

2L

12V

1

3

2

10R10

B

0.85

B

2B

2R WB

r

2B 5R

+ -

W/Y

B3B

R

B

Y

+-B L YG RB

2W2B

2B

5R

2W

2B

0.85B

1197

17

1192

47-7

7100

1202

70-7

7511

1289

90-7

7910

-778

00

0.85WBr

2R

A A3R

3WYW

WL

WG

BRB

LBO

YG3L

+-

PO

0

0

47Ω

/3W

1N40

07

L

WB

r

W R L YW

R

B

YWWLYGLB

RB

RBRB

B

BR

B

II

II

I

I

SYSTEM DIAGRAMS


12/05


1 – Optional2 – Diodes3 – Buzzer4 – Oil Pressure5 – Coolant Temperature6 – Sail Drive Seal7 – Charge8 – Fuse 3A9 – SWITCH GLOW (I) / OFF (0) /

STOP (II)10 – SWITCH START (II) / ON (I) /

OFF (0)11 – Diode12 – Switch13 – Tachometer Hour Meter14 – Instrument Panel (main station)

(option)15 – Wire Harness16 – Wire Harness for Sub Panel

17 – Amplifier (only for sail drive)18 – Procured by Customer19 – Battery20 – Battery Switch21 – Engine Stop Solenoid22 – Relay23 – Glow Plug24 – Stop Relay25 – Starter Relay26 – Starter27 – Coolant Temperature Switch28 – Engine Oil Pressure Switch29 – Alternator30 – Ground31 – Sail Drive (only for sail drive)32 – Coupler (view from A-A)

SYSTEM DIAGRAMS




YM Series Operation ManualEPA WARRANTY USA ONLY

YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM WARRANTY - USA ONLY

2YM15 / 3YM20 EPA and CARB Nameplate

For Example (2YM15)

Figure 1

3YM30 EPA and CARB Nameplate

Figure 2

YANMAR CO., LTD.

��

STANDARDS NOx+HC: 7.5g/kW-hr CO: 6.6g/kW-hr PM: 0.40g/kW-hr

EMISSION CONTROL INFORMATIONTHIS ENGINE COMPLIES WITH U.S. EPA MARINE AND CALIFORNIA OFF-ROADREGULATIONS FOR 2009 M.Y. DIESEL ENGINES.LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY.ENGINE FAMILY: 9YDXN0.57P2N DISPLACEMENT: 0.569 LITERSENGINE MODEL: 2YM15 EMISSION CONTROL SYSTEM: EMFUEL RATE: 17.4MM3/STROKE @ 10.0kW / 3600RPM (8≤kW<19)

APPLICATION: VARIABLE-SPEED PROPULSION ENGINES USED WITH FIXED-PITCH PROPELLERS.

YANMAR CO., LTD.

��

STANDARDS NOx+HC: 7.5g/kW-hr CO: 5.5g/kW-hr PM: 0.30g/kW-hr

EMISSION CONTROL INFORMATIONTHIS ENGINE COMPLIES WITH U.S. EPA MARINE AND CALIFORNIA OFF-ROADREGULATIONS FOR 2009 M.Y. DIESEL ENGINES.LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY.ENGINE FAMILY: 9YDXN1.11P3N DISPLACEMENT: 1.116 LITERSENGINE MODEL: 3YM30 EMISSION CONTROL SYSTEM: EMFUEL RATE: 23.2MM3/STROKE @ 21.3kW / 3600RPM (19≤kW<37)

APPLICATION: VARIABLE-SPEED PROPULSION ENGINES USED WITH FIXED-PITCH PROPELLERS.

EPA WARRANTY USA ONLY


THIS EMISSION WARRANTY APPLIES TO THE ENGINES CERTIFIED TO UNITED STATES EPA 40 CFR AND SOLD BY YANMAR THAT ARE INSTALLED IN VESSELS FLAGGED OR REGISTERED IN THE UNITED STATES.

Your Warranty Rights and Obligations:Yanmar warrants to the first user and each subsequent purchaser the emission control system on your engine for periods of time listed below provided the engine has been installed according to Yanmar installation requirements and there has been no abuse, neglect, or improper maintenance of your Yanmar Marine engine.

Yanmar warrants that the engine is designed, built and tested using genuine parts and equipped so as to conform to all applicable emission requirements of the U.S. Environmental Protection Agency and is free from defects in material and workmanship which would cause this engine to fail to conform to the applicable emission regulations over its limited emission control system warranty period.

Where a warrantable emissions condition exists, Yanmar will repair your engine at no charge to you for diagnosis, parts, and labor. Warranty service or repair will be provided at authorized Yanmar Marine dealers or distributors.

It is recommended that any replacement parts used for maintenance, repair or replacement of emission control systems are Yanmar parts. The owner may elect to have maintenance, replacement or repair of the emission control components and systems performed by any repair establishment or individual and may elect to use parts other than Yanmar parts for such maintenance, replacement or repair. However, the cost of such service or parts and subsequent failures from such service or parts will not be covered under this emission control system warranty:

Warranty Period:The warranty starts on either the date of delivery to the first end-user, or the date the unit is first leased, rented, or loaned.

When a measurement device of use hours is not equipped, warranties apply a period of use months.

Engine Model Warranty Period

2YM15, 3YM20(kW < 19)

30 months or 1,500 hours of use, whichever comes first.

3YM30(19 ≤ kW < 37)




12/05


Warranty Coverage:Repair or replacement of any warranted parts will be performed at an authorized Yanmar dealer or distributor. This limited emission control system warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser. Such components may include the following:

• Fuel Injection System

• Turbocharger System

• Aftercooler

• Electronic Engine Control Units and its associated Sensor and Actuators

Exclusions:Failures other than those arising from defects in material and / or workmanship are not covered by this limited emissions warranty. This warranty does not extend to the following: malfunction caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance, improper storage or use of non-recommended fuels and lubricating oils, accident-caused damage, and replacement of expendable and / or consumable items made in connection with scheduled maintenance.

Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time, inconvenience, loss of use of marine vessel / engine or commercial loss.

Owner’s Responsibility:As the Yanmar Marine engine owner, you are responsible for the performance of the required maintenance listed in your Operation Manual. Yanmar recommends that you retain all documentation, including receipts, covering maintenance on your marine engine, but Yanmar cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with applicable emission requirements. You are responsible for initiating the warranty process. You must present your marine engine to an authorized Yanmar dealer or distributor as soon as a problem exists.



Customer Assistance:If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar dealer or distributor, you should contact Yanmar Marine USA Corporation for assistance.

Yanmar Marine USA Corporation101 International ParkwayAdairsville, GA 30103 USA Telephone: 770-877-9894Fax: 770-877-7567


YM Series Operation ManualEMISSION SYSTEM WARRANTY

NON-ROAD EMISSION SYSTEM WARRANTYYanmar Co., Ltd. Limited Emission Control System Warranty - USA Only

Your Warranty Rights and Obligations:

Note: Please refer to Yanmar’s Limited Warranty Handbook for a description of the normal (non-EPA) warranty.

California

The California Air Resources Board (CARB), the Environmental Protection Agency (EPA) and Yanmar Co., Ltd. hereafter referred to as Yanmar, are pleased to explain the emission control system warranty on your compression-ignition engine. In California, model year 2000 or later off-road compression-ignition engines must be designed, built and equipped to meet the state’s stringent anti-smog standards. In all states, 1998 and later non-road compression-ignition engines must be designed, built and equipped to meet the United States EPA emissions standards. Yanmar warrants the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine.

Your emission control system may include parts such as the fuel injection system and the air induction system.

Where a warrantable condition exists, Yanmar will repair your non-road compression-ignition engine at no charge to you including diagnosis, parts and labor.

Manufacturer’s Warranty Period:

The model year 1998 or later certified and labeled non-road compression-ignition engines are warranted for the periods listed below. If any emission-related part on your engine is found to be defective during the applicable warranty period, the part will be replaced by Yanmar.

When a measurement device of use hours is not equipped, warranties apply a period of use months.

Engine Model Warranty Period

2YM15, 3YM20(kW < 19)


3YM30(19 ≤ kW < 37)


EMISSION SYSTEM WARRANTY


Warranty Coverage:

This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or replacement of any warranted part will be performed at an authorized Yanmar Marine engine dealer or distributor.

Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in the operation manual are warranted for the period of time prior to the first scheduled replacement. Any part repaired or replaced under warranty shall be warranted for the remaining warranty period.

During the warranty period, Yanmar is liable for damages to other engine components caused by the failure of any warranted part during the warranty period.

Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine, and shall not reduce Yanmar’s warranty obligations. Add-on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or modified parts shall be grounds for disallowing a warranty.

Warranted Parts:

This warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser. Such components may include the following:

• Fuel Injection System

• Cold Start Enrichment System

• Positive Crankcase Ventilation System

Since emissions-related parts may vary slightly between models, certain models may not contain all of these parts and other models may contain the functional equivalents.

Exclusions:

Failures other than those arising from defects in material and / or workmanship are not covered by this warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance or use of non-recommended fuels and lubricating oils; accident-caused damage, and replacement of expendable items made in connection with scheduled maintenance. Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time, inconvenience, loss of use of equipment / engine or commercial loss.

Owner’s Warranty Responsibilities:

As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Yanmar recommends that you retain all documentation, including receipts, covering maintenance on your non-road compression-ignition engine, but Yanmar cannot deny warranty solely for the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.

Yanmar may deny your warranty coverage of your non-road compression-ignition engine if a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with applicable emissions requirements.



12/05


You are responsible for initiating the warranty process. You must present your engine to a Yanmar dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.

Customer Assistance

If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar dealer or distributor, you should contact Yanmar Marine USA Corporation for assistance.

Yanmar Marine USA Corporation

101 International ParkwayAdairsville, GA 30103 USATelephone: 770-877-9894Fax: 770-877-7567



Maintenance Log

Date OperatingHours

Maintenance Performed Dealer Name Stamp or Signature



12/05


Date OperatingHours

Maintenance Performed Dealer Name Stamp or Signature

ym om v2 cover - j/109j109.org/docs/yanmar_ym_series_operations_manual_v2_21... · 2015. 2. 3. ·...

Documents